Modular exoskeleton systems and methods

ABSTRACT

A method of operating a modular exoskeleton system, the method comprising: monitoring for one or more actuator units being operably coupled to or removed from the modular exoskeleton system, the modular exoskeleton system comprising at least a first actuator unit configured to be operably coupled and removed from the modular exoskeleton system; determining that the first actuator unit has been operably coupled to the modular exoskeleton system; determining the first actuator unit has been associated with a first body portion of the user; determining a first new operating configuration based at least in part on the determination that the first actuator unit has been operably coupled to the modular exoskeleton system and the determination that the first actuator unit has been associated with the first body portion of the user; and setting the first new operating configuration for the modular exoskeleton system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims priority to U.S.Provisional Patent Application No. 63/030,586, filed May 27, 2020,entitled “POWERED DEVICE FOR IMPROVED USER MOBILITY AND MEDICALTREATMENT,” with attorney docket number 0110496-010PR0. This applicationis hereby incorporated herein by reference in its entirety and for allpurposes.

This application is a non-provisional of and claims priority to U.S.Provisional Patent Application No. 63/058,825, filed Jul. 30, 2020,entitled “POWERED DEVICE TO BENEFIT A WEARER DURING TACTICALAPPLICATIONS,” with attorney docket number 0110496-011PRO. Thisapplication is hereby incorporated herein by reference in its entiretyand for all purposes.

This application is also related to U.S. Non-Provisional applicationsfiled the same day as this application having attorney docket numbers0110496-010US0, 0110496-012US0, 0110496-013US0, 0110496-014US0,0110496-015US0 and 0110496-016US0, respectively entitled “POWEREDMEDICAL DEVICE AND METHODS FOR IMPROVED USER MOBILITY AND TREATMENT”,“FIT AND SUSPENSION SYSTEMS AND METHODS FOR A MOBILE ROBOT”, “BATTERYSYSTEMS AND METHODS FOR A MOBILE ROBOT”, “CONTROL SYSTEM AND METHOD FORA MOBILE ROBOT”, “USER INTERFACE AND FEEDBACK SYSTEMS AND METHODS FOR AMOBILE ROBOT”, and “DATA LOGGING AND THIRD-PARTY ADMINISTRATION OF AMOBILE ROBOT” and having respective application Ser. Nos. ______,______, ______, ______, ______ and ______, These applications are herebyincorporated herein by reference in their entirety and for all purposes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example illustration of an embodiment of an exoskeletonsystem being worn by a user.

FIG. 2 is a front view of an embodiment of a leg actuation unit coupledto one leg of a user.

FIG. 3 is a side view of the leg actuation unit of FIG. 3 coupled to theleg of the user.

FIG. 4 is a perspective view of the leg actuation unit of FIGS. 3 and 4.

FIG. 5 is a block diagram illustrating an example embodiment of anexoskeleton system having a left and right leg actuator.

FIG. 6 is a rear view of another embodiment of an exoskeleton systemincluding a leg actuator unit coupled to the right leg of a user.

FIG. 7 is a close-up view of a portion of the illustration of FIG. 6.

FIG. 8 is a side view of the embodiment of the exoskeleton system ofFIGS. 6 and 7.

FIG. 9 is a front view of the exoskeleton system of FIGS. 6-8.

FIG. 10 is a perspective view of the leg actuation unit shown in FIGS.6-9.

FIG. 11 is a block diagram illustrating an example embodiment of anexoskeleton system having a right leg actuator.

FIG. 12 is a block diagram illustrating an example embodiment of anexoskeleton system having a left leg actuator.

FIG. 13 illustrates an example method of operating a modular exoskeletonsystem in accordance with one embodiment.

FIG. 14a illustrates a side view of a pneumatic actuator in a compressedconfiguration in accordance with one embodiment.

FIG. 14b illustrates a side view of the pneumatic actuator of FIG. 14ain an expanded configuration.

FIG. 15a illustrates a cross-sectional side view of a pneumatic actuatorin a compressed configuration in accordance with another embodiment.

FIG. 15b illustrates a cross-sectional side view of the pneumaticactuator of FIG. 13a in an expanded configuration.

FIG. 16a illustrates a top view of a pneumatic actuator in a compressedconfiguration in accordance with another embodiment.

FIG. 16b illustrates a top of the pneumatic actuator of FIG. 16a in anexpanded configuration.

FIG. 17 illustrates a top view of a pneumatic actuator constraint rib inaccordance with an embodiment.

FIG. 18a illustrates a cross-sectional view of a pneumatic actuatorbellows in accordance with another embodiment.

FIG. 18b illustrates a side view of the pneumatic actuator of FIG. 18ain an expanded configuration showing the cross section of FIG. 18 a.

FIG. 19 illustrates an example planar material that is substantiallyinextensible along one or more plane axes of the planar material whilebeing flexible in other directions.

It should be noted that the figures are not drawn to scale and thatelements of similar structures or functions are generally represented bylike reference numerals for illustrative purposes throughout thefigures. It also should be noted that the figures are only intended tofacilitate the description of the preferred embodiments. The figures donot illustrate every aspect of the described embodiments and do notlimit the scope of the present disclosure.

DETAILED DESCRIPTION

The following disclosure also includes example embodiments of the designof novel exoskeleton devices. Various preferred embodiments include: aleg brace with integrated actuation, a mobile power source and a controlunit that determines the output behavior of the device in real-time.

A component of an exoskeleton system that is present in variousembodiments is a body-worn, lower-extremity brace that incorporates theability to introduce torque to the user. One preferred embodiment ofthis component is a leg brace that is configured to support the knee ofthe user and includes actuation across the knee joint to provideassistance torques in the extension direction. This embodiment canconnect to the user through a series of attachments including one on theboot, below the knee, and along the user's thigh. This preferredembodiment can include this type of leg brace on both legs of the user.

The present disclosure teaches example embodiments of a fluidicexoskeleton system that includes one or more adjustable fluidicactuators. Some preferred embodiments include a fluidic actuator thatcan be operated at various pressure levels with a large stroke length ina configuration that can be oriented with a joint on a human body.

In some cases, the system can be designed to support multipleconfigurations in a modular configuration. A preferred embodiment is amodular configuration that is designed to operate in either asingle-knee configuration or in a dual-knee configuration as a functionof how many of the brace components or actuation units are donned by theuser. Yet another embodiment can use a single fluidic and electric powerpack to power an assistive knee brace on one leg, and a below kneeprosthetic on the other leg.

In a modular configuration, in some embodiments it may be required thata single fluidic and electric power pack be configured to support thefluidic and electrical power requirements of various potentialconfigurations. One preferred configuration is a fluidic and electricalpower supply that can be configured to power a dual-knee configurationor a single-knee configuration. In various embodiments, such a fluidicand electrical power supply would need to support the power requirementsof both configurations and then appropriately direct the fluidic andelectrical power to operate effectively in a given configuration.Various embodiments exist to support the array of potential modularsystem configurations, such as multiple batteries, more than twoactuator units, more than one power pack, etc.

In the example case of a modular exoskeleton system, it can be desirablein some embodiments for operational control software to operate with anunderstanding of which actuation units are operational within thesystem. In one embodiment of a modular dual-knee system that can alsooperate in a single-knee configuration, operational control software cangenerate references differently when in a two-leg configuration and whenin a single-leg configuration. Specifically, such an embodiment may usea coordinated control approach to generate references where it is usinginputs from both legs to determine the desired operation; however, in asingle-leg configuration, the available sensor information may havechanged, so the system can implement a different strategy based ondifferent sensor information being available. In various embodimentsthis can be done to maximize the performance of the system for the givenconfiguration or account for variations in available sensor information.For clarity, these embodiments are not limited to the examples givenabove and include any combination of configurations of actuation units,power packs, as well as any related sensor information that can beassociated with actuation units, power packs, or sensors independentlylocated on the user.

Another unique consideration in some examples of operational controlsoftware can be if a user's needs are different between individual bodyjoints, such as between the left or right knee. In such a scenario, itmay be beneficial for the exoskeleton system to change the torquereferences generated in each leg to tailor the experience for the user.One example embodiment is that of a dual-knee exoskeleton where a userhas significant pain issues in a single leg, but not in the other leg.In such a case, the system can include the ability for the system toscale the output torques on the unaffected limb to best meet the needsof the user.

As discussed herein, an exoskeleton system 100 can be configured forvarious suitable uses. For example, FIGS. 1-3 illustrate an exoskeletonsystem 100 being used by a user. As shown in FIG. 1 the user 101 canwear the exoskeleton system 100 on both legs 102. FIGS. 2 and 3illustrate a front and side view of an actuator unit 110 coupled to aleg 102 of a user 101 and FIG. 4 illustrates a side view of an actuatorunit 110 not being worn by a user 101.

As shown in the example of FIG. 1, the exoskeleton system 100 cancomprise a left and right leg actuator unit 110L, 110R that arerespectively coupled to a left and right leg 102L, 102R of the user. Invarious embodiments, the left and right leg actuator units 110L, 110Rcan be substantially mirror images of each other.

As shown in FIGS. 1-4, leg actuator units 110 can include an upper arm115 and a lower arm 120 that are rotatably coupled via a joint 125. Abellows actuator 130 extends between the upper arm 115 and lower arm120. One or more sets of pneumatic lines 145 can be coupled to thebellows actuator 130 to introduce and/or remove fluid from the bellowsactuator 130 to cause the bellows actuator 130 to expand and contractand to stiffen and soften, as discussed herein. A backpack 155 can beworn by the user 101 and can hold various components of the exoskeletonsystem 100 such as a fluid source, control system, a power source, andthe like.

As shown in FIGS. 1-3, the leg actuator units 110L, 110R can berespectively coupled about the legs 102L, 102R of the user 101 with thejoints 125 positioned at the knees 103L, 103R of the user 101 with theupper arms 115 of the leg actuator units 110L, 110R being coupled aboutthe upper legs portions 104L, 104R of the user 101 via one or morecouplers 150 (e.g., straps that surround the legs 102). The lower arms120 of the leg actuator units 110L, 110R can be coupled about the lowerleg portions 105L, 105R of the user 101 via one or more couplers 150.

The upper and lower arms 115, 120 of a leg actuator unit 110 can becoupled about the leg 102 of a user 101 in various suitable ways. Forexample, FIGS. 1-3 illustrates an example where the upper and lower arms115, 120 and joint 125 of the leg actuator unit 110 are coupled alonglateral faces (sides) of the top and bottom portions 104, 105 of the leg102. As shown in the example of FIGS. 1-3, the upper arm 115 can becoupled to the upper leg portion 104 of a leg 102 above the knee 103 viatwo couplers 150 and the lower arm 120 can be coupled to the lower legportion 105 of a leg 102 below the knee 103 via two couplers 150.

Specifically, upper arm 115 can be coupled to the upper leg portion 104of the leg 102 above the knee 103 via a first set of couplers 250A thatincludes a first and second coupler 150A, 150B. The first and secondcouplers 150A, 150B can be joined by a rigid plate assembly 215 disposedon a lateral side of the upper leg portion 104 of the leg 102, withstraps 151 of the first and second couplers 150A, 150B extending aroundthe upper leg portion 104 of the leg 102. The upper arm 115 can becoupled to the plate assembly 215 on a lateral side of the upper legportion 104 of the leg 102, which can transfer force generated by theupper arm 115 to the upper leg portion 104 of the leg 102.

The lower arm 120 can be coupled to the lower leg portion 105 of a leg102 below the knee 103 via second set of couplers 250B that includes athird and fourth coupler 150C, 150D. A coupling branch unit 220 canextend from a distal end of, or be defined by a distal end of the lowerarm 120. The coupling branch unit 220 can comprise a first branch 221that extends from a lateral position on the lower leg portion 105 of theleg 102, curving upward and toward the anterior (front) of the lower legportion 105 to a first attachment 222 on the anterior of the lower legportion 105 below the knee 103, with the first attachment 222 joiningthe third coupler 150C and the first branch 221 of the coupling branchunit 220. The coupling branch unit 220 can comprise a second branch 223that extends from a lateral position on the lower leg portion 105 of theleg 102, curving downward and toward the posterior (back) of the lowerleg portion 105 to a second attachment 224 on the posterior of the lowerleg portion 105 below the knee 103, with the second attachment 224joining the fourth coupler 150D and the second branch 223 of thecoupling branch unit 220.

As shown in the example of FIGS. 1-3, the fourth coupler 150D can beconfigured to surround and engage the boot 191 of a user. For example,the strap 151 of the fourth coupler 150D can be of a size that allowsthe fourth coupler 150D to surround the larger diameter of a boot 191compared to the lower portion 105 of the leg 102 alone. Also, the lengthof the lower arm 120 and/or coupling branch unit 220 can be of a lengthsufficient for the fourth coupler 150D to be positioned over a boot 191instead of being of a shorter length such that the fourth coupler 150Dwould surround a section of the lower portion 105 of the leg 102 abovethe boot 191 when the leg actuator unit 110 is worn by a user.

Attaching to the boot 191 can vary across various embodiments. In oneembodiment, this attachment can be accomplished through a flexible strapthat wraps around the circumference of boot 191 to affix the legactuator unit 110 to the boot 191 with the desired amount of relativemotion between the leg actuator unit 110 and the strap. Otherembodiments can work to restrict various degrees of freedom whileallowing the desired amount of relative motion between the leg actuatorunit 110 and the boot 191 in other degrees of freedom. One suchembodiment can include the use of a mechanical clip that connects to theback of the boot 191 that can provide a specific mechanical connectionbetween the device and the boot 191. Various embodiments can include butare not limited to the designs listed previously, a mechanical boltedconnection, a rigid strap, a magnetic connection, an electro-magneticconnection, an electromechanical connection, an insert into the user'sboot, a rigid or flexible cable, or a connection directly to a boot.

Another aspect of the exoskeleton system 100 can be fit components usedto secure the exoskeleton system 100 to the user 101. Since the functionof the exoskeleton system 100 in various embodiments can rely heavily onthe fit of the exoskeleton system 100 efficiently transmitting forcesbetween the user 101 and the exoskeleton system 100 without theexoskeleton system 100 significantly drifting on the body 101 orcreating discomfort, improving the fit of the exoskeleton system 100 andmonitoring the fit of the exoskeleton system 100 to the user over timecan be desirable for the overall function of the exoskeleton system 100in some embodiments.

In various examples, different couplers 150 can be configured fordifferent purposes, with some couplers 150 being primarily for thetransmission of forces, with others being configured for secureattachment of the exoskeleton system 100 to the body 101. In onepreferred embodiment for a single knee system, a coupler 150 that sitson the lower leg 105 of the user 101 (e.g., one or both of couplers150C, 150D) can be intended to target body fit, and as a result, canremain flexible and compliant to conform to the body of the user 101.Alternatively, in this embodiment a coupler 150 that affixes to thefront of the user's thigh on an upper portion 104 of the leg 102 (e.g.,one or both of couplers 150A, 150B) can be intended to target powertransmission needs and can have a stiffer attachment to the body thanother couplers 150 (e.g., one or both of couplers 150C, 150D). Variousembodiments can employ a variety of strapping or couplingconfigurations, and these embodiments can extend to include any varietyof suitable straps, couplings, or the like, where two parallel sets ofcoupling configurations are meant to fill these different needs.

In some cases the design of the joint 125 can improve the fit of theexoskeleton system 100 on the user. In one embodiment, the joint 125 ofa single knee leg actuator unit 110 can be designed to use a singlepivot joint that has some deviations with the physiology of the kneejoint. Another embodiment, uses a polycentric knee joint to better fitthe motion of the human knee joint, which in some examples can bedesirably paired with a very well fit leg actuator unit 110. Variousembodiments of a joint 125 can include but are not limited to theexample elements listed above, a ball and socket joint, a four barlinkage, and the like.

Some embodiments can include fit adjustments for anatomical variationsin varus or valgus angles in the lower leg 105. One preferred embodimentincludes an adjustment incorporated into a leg actuator unit 110 in theform of a cross strap that spans the joint of the knee 103 of the user101, which can be tightened to provide a moment across the knee joint inthe frontal plane which varies the nominal resting angle. Variousembodiments can include but are not limited to the following: a strapthat spans the joint 125 to vary the operating angle of the joint 125; amechanical assembly including a screw that can be adjusted to vary theangle of the joint 125; mechanical inserts that can be added to the legactuator unit 110 to discreetly change the default angle of the joint125 for the user 101, and the like.

In various embodiments, the leg actuator unit 110 can be configured toremain suspended vertically on the leg 102 and remain appropriatelypositioned with the joint of the knee 103. In one embodiment, coupler150 associated with a boot 191 (e.g., coupler 150D) can provide avertical retention force for a leg actuator unit 110. Another embodimentuses a coupler 150 positioned on the lower leg 105 of the user 101(e.g., one or both of couplers 150C, 150D) that exerts a vertical forceon the leg actuator unit 110 by reacting on the calf of the user 101.Various embodiments can include but are not limited to the following:suspension forces transmitted through a coupler 150 on the boot (e.g.,coupler 150D) or another embodiment of the boot attachment discussedpreviously; suspension forces transmitted through an electronic and/orfluidic cable assembly; suspension forces transmitted through aconnection to a waist belt; suspension forces transmitted through amechanical connection to a backpack 155 or other housing for theexoskeleton device 510 and/or pneumatic system 520 (see FIG. 5);suspension forces transmitted through straps or a harness to theshoulders of the user 101, and the like.

In various embodiments, a leg actuator unit 110 can be spaced apart fromthe leg 102 of the user with a limited number of attachments to the leg102. For example, in some embodiments, the leg actuator unit 110 canconsist or consist essentially of three attachments to the leg 102 ofthe user 101, namely via the first and second attachments 222, 224 and215. In various embodiments, the couplings of the leg actuator unit 110to the lower leg portion 105 can consist or consist essentially of afirst and second attachment on the anterior and posterior of the lowerleg portion 105. In various embodiments, the coupling of the legactuator unit 110 to the upper leg portion 104 can consist or consistessentially of a single lateral coupling, which can be associated withone or more couplers 150 (e.g., two couplers 150A, 150B as shown inFIGS. 1-4). In various embodiments, such a configuration can bedesirable based on the specific force-transfer for use during a subjectactivity. Accordingly, the number and positions of attachments orcoupling to the leg 102 of the user 101 in various embodiments is not asimple design choice and can be specifically selected for one or moreselected target user activities.

While specific embodiments of couplers 150 are illustrated herein, infurther embodiments, such components discussed herein can be operablyreplaced by an alternative structure to produce the same functionality.For example, while straps, buckles, padding and the like are shown invarious examples, further embodiments can include couplers 150 ofvarious suitable types and with various suitable elements. For example,some embodiments can include Velcro hook-and-loop straps, or the like.

FIGS. 1-3 illustrate an example of an exoskeleton system 100 where thejoint 125 is disposed laterally and adjacent to the knee 103 with arotational axis of the joint 125 being disposed parallel to a rotationalaxis of the knee 103. In some embodiments, the rotational axis of thejoint 125 can be coincident with the rotational axis of the knee 103. Insome embodiments, a joint can be disposed on the anterior of the knee103, posterior of the knee 103, inside of the knee 103, or the like.

In various embodiments, the joint structure 125 can constrain thebellows actuator 130 such that force created by actuator fluid pressurewithin the bellows actuator 130 can be directed about an instantaneouscenter (which may or may not be fixed in space). In some cases of arevolute or rotary joint, or a body sliding on a curved surface, thisinstantaneous center can coincide with the instantaneous center ofrotation of the joint 125 or a curved surface. Forces created by a legactuator unit 110 about a rotary joint 125 can be used to apply a momentabout an instantaneous center as well as still be used to apply adirected force. In some cases of a prismatic or linear joint (e.g., aslide on a rail, or the like), the instantaneous center can bekinematically considered to be located at infinity, in which case theforce directed about this infinite instantaneous center can beconsidered as a force directed along the axis of motion of the prismaticjoint. In various embodiments, it can be sufficient for a rotary joint125 to be constructed from a mechanical pivot mechanism. In such anembodiment, the joint 125 can have a fixed center of rotation that canbe easy to define, and the bellows actuator 130 can move relative to thejoint 125. In a further embodiment, it can be beneficial for the joint125 to comprise a complex linkage that does not have a single fixedcenter of rotation. In yet another embodiment, the joint 125 cancomprise a flexure design that does not have a fixed joint pivot. Instill further embodiments, the joint 125 can comprise a structure, suchas a human joint, robotic joint, or the like.

In various embodiments, leg actuator unit 110 (e.g., comprising bellowsactuator 130, joint structure 125, and the like) can be integrated intoa system to use the generated directed force of the leg actuator unit110 to accomplish various tasks. In some examples, a leg actuator unit110 can have one or more unique benefits when the leg actuator unit 110is configured to assist the human body or is included into a poweredexoskeleton system 100. In an example embodiment, the leg actuator unit110 can be configured to assist the motion of a human user about theuser's knee joint 103. To do so, in some examples, the instantaneouscenter of the leg actuator unit 110 can be designed to coincide ornearly coincide with the instantaneous center of rotation of the knee103 of a user 101. In one example configuration, the leg actuator unit110 can be positioned lateral to the knee joint 103 as shown in FIGS.1-3. In various examples, the human knee joint 103 can function as(e.g., in addition to or in place of) the joint 125 of the leg actuatorunit 110.

For clarity, example embodiments discussed herein should not be viewedas a limitation of the potential applications of the leg actuator unit110 described within this disclosure. The leg actuator unit 110 can beused on other joints of the body including but not limited to one ormore elbow, one or more hip, one or more finger, one or more ankle,spine, or neck. In some embodiments, the leg actuator unit 110 can beused in applications that are not on the human body such as in robotics,for general purpose actuation, animal exoskeletons, or the like.

Also, embodiments can be used for or adapted for various suitableapplications such as tactical, medical, or labor applications, and thelike. Examples of such applications can be found in U.S. patentapplication Ser. No. 15/823,523, filed Nov. 27, 2017 entitled “PNEUMATICEXOMUSCLE SYSTEM AND METHOD” with attorney docket number 0110496-002US1and U.S. patent application Ser. No. 15/953,296, filed Apr. 13, 2018entitled “LEG EXOSKELETON SYSTEM AND METHOD” with attorney docket number0110496-004US0, which are incorporated herein by reference.

Some embodiments can apply a configuration of a leg actuator unit 110 asdescribed herein for linear actuation applications. In an exampleembodiment, the bellows actuator 130 can comprise a two-layerimpermeable/inextensible construction, and one end of one or moreconstraining ribs can be fixed to the bellows actuator 130 atpredetermined positions. The joint structure 125 in various embodimentscan be configured as a series of slides on a pair of linear guide rails,where the remaining end of one or more constraining ribs is connected toa slide. The motion and force of the fluidic actuator can therefore beconstrained and directed along the linear rail.

FIG. 5 is a block diagram of an example embodiment of an exoskeletonsystem 100 that includes an exoskeleton device 510 that is operablyconnected to a pneumatic system 520. While a pneumatic system 520 isused in the example of FIG. 5, further embodiments can include anysuitable fluidic system or a pneumatic system 520 can be absent in someembodiments, such as where an exoskeleton system 100 is actuated byelectric motors, or the like.

The exoskeleton device 510 in this example comprises a processor 511, amemory 512, one or more sensors 513 a communication unit 514, a userinterface 515 and a power source 516. A plurality of actuators 130 areoperably coupled to the pneumatic system 520 via respective pneumaticlines 145. The plurality of actuators 130 include a pair ofknee-actuators 130L and 130R that are positioned on the right and leftside of a body 100. For example, as discussed above, the exampleexoskeleton system 100 shown in FIG. 5 can comprise a left and right legactuator unit 110L, 110R on respective sides of the body 101 as shown inFIGS. 1 and 2 with one or both of the exoskeleton device 510 andpneumatic system 520, or one or more components thereof, stored withinor about a backpack 155 (see FIG. 1) or otherwise mounted, worn or heldby a user 101.

Accordingly, in various embodiments, the exoskeleton system 100 can be acompletely mobile and self-contained system that is configured to bepowered and operate for an extended period of time without an externalpower source during various user activities. The size, weight andconfiguration of the actuator unit(s) 110, exoskeleton device 510 andpneumatic system 520 can therefore be configured in various embodimentsfor such mobile and self-contained operation.

In various embodiments, the example system 100 can be configured to moveand/or enhance movement of the user 101 wearing the exoskeleton system100. For example, the exoskeleton device 510 can provide instructions tothe pneumatic system 520, which can selectively inflate and/or deflatethe bellows actuators 130 via pneumatic lines 145. Such selectiveinflation and/or deflation of the bellows actuators 130 can move and/orsupport one or both legs 102 to generate and/or augment body motionssuch as walking, running, jumping, climbing, lifting, throwing,squatting, skiing or the like.

In some cases, the exoskeleton system 100 can be designed to supportmultiple configurations in a modular configuration. For example, oneembodiment is a modular configuration that is designed to operate ineither a single knee configuration or in a double knee configuration asa function of how many of the actuator units 110 are donned by the user101. For example, the exoskeleton device 510 can determine how manyactuator units 110 are coupled to the pneumatic system 520 and/orexoskeleton device 510 (e.g., on or two actuator units 110) and theexoskeleton device 510 can change operating capabilities based on thenumber of actuator units 110 detected.

In further embodiments, the pneumatic system 520 can be manuallycontrolled, configured to apply a constant pressure, or operated in anyother suitable manner. In some embodiments, such movements can becontrolled and/or programmed by the user 101 that is wearing theexoskeleton system 100 or by another person. In some embodiments, theexoskeleton system 100 can be controlled by movement of the user 101.For example, the exoskeleton device 510 can sense that the user iswalking and carrying a load and can provide a powered assist to the uservia the actuators 130 to reduce the exertion associated with the loadand walking. Similarly, where a user 101 wears the exoskeleton system100, the exoskeleton system 100 can sense movements of the user 101 andcan provide a powered assist to the user via the actuators 130 toenhance or provide an assist to the user while skiing.

Accordingly, in various embodiments, the exoskeleton system 130 canreact automatically without direct user interaction. In furtherembodiments, movements can be controlled in real-time by user interface515 such as a controller, joystick, voice control or thought control.Additionally, some movements can be pre-preprogrammed and selectivelytriggered (e.g., walk forward, sit, crouch) instead of being completelycontrolled. In some embodiments, movements can be controlled bygeneralized instructions (e.g. walk from point A to point B, pick up boxfrom shelf A and move to shelf B).

The user interface 515 can allow the user 101 to control various aspectsof the exoskeleton system 100 including powering the exoskeleton system100 on and off; controlling movements of the exoskeleton system 100;configuring settings of the exoskeleton system 100, and the like. Theuser interface 515 can include various suitable input elements such as atouch screen, one or more buttons, audio input, and the like. The userinterface 515 can be located in various suitable locations about theexoskeleton system 100. For example, in one embodiment, the userinterface 515 can be disposed on a strap of a backpack 155, or the like.In some embodiments, the user interface can be defined by a user devicesuch as smartphone, smart-watch, wearable device, or the like.

In various embodiments, the power source 516 can be a mobile powersource that provides the operational power for the exoskeleton system100. In one preferred embodiment, the power pack unit contains some orall of the pneumatic system 520 (e.g., a compressor) and/or power source(e.g., batteries) required for the continued operation of pneumaticactuation of the leg actuator units 110. The contents of such a powerpack unit can be correlated to the specific actuation approachconfigured to be used in the specific embodiment. In some embodiments,the power pack unit will only contain batteries which can be the case inan electromechanically actuated system or a system where the pneumaticsystem 520 and power source 516 are separate. Various embodiments of apower pack unit can include but are not limited to a combination of theone or more of the following items: pneumatic compressor, batteries,stored high-pressure pneumatic chamber, hydraulic pump, pneumatic safetycomponents, electric motor, electric motor drivers, microprocessor, andthe like. Accordingly, various embodiments of a power pack unit caninclude one or more of elements of the exoskeleton device 510 and/orpneumatic system 520.

Such components can be configured on the body of a user 101 in a varietyof suitable ways. One preferred embodiment is the inclusion of a powerpack unit in a torso-worn pack that is not operably coupled to the legactuator units 110 in any manner that transmits substantial mechanicalforces to the leg actuator units 110. Another embodiment includes theintegration of the power pack unit, or components thereof, into the legactuator units 110 themselves. Various embodiments can include but arenot limited to the following configurations: torso-mounted in abackpack, torso-mounted in a messenger bag, hip-mounted bag, mounted tothe leg, integrated into the brace component, and the like. Furtherembodiments can separate the components of the power pack unit anddisperse them into various configurations on the user 101. Such anembodiment may configure a pneumatic compressor on the torso of the user101 and then integrate the batteries into the leg actuator units 110 ofthe exoskeleton system 100.

One aspect of the power supply 516 in various embodiments is that itmust be connected to the brace component in such a manner as to pass theoperable system power to the brace for operation. One preferredembodiment is the use of electrical cables to connect the power supply516 and the leg actuator units 110. Other embodiments can use electricalcables and a pneumatic line 145 to deliver electrical power andpneumatic power to the leg actuator units 110. Various embodiments caninclude but are not limited to any configuration of the followingconnections: pneumatic hosing, hydraulic hosing, electrical cables,wireless communication, wireless power transfer, and the like.

In some embodiments, it can be desirable to include secondary featuresthat extend the capabilities of a cable connection (e.g., pneumaticlines 145 and/or power lines) between the leg actuator units 110 and thepower supply 516 and/or pneumatic system 520. One preferred embodimentincludes retractable cables that are configured to have a smallmechanical retention force to maintain cables that are pulled tightagainst the user with reduced slack remaining in the cable. Variousembodiments can include, but are not limited to a combination of thefollowing secondary features: retractable cables, a single cableincluding both fluidic and electrical power, magnetically-connectedelectrical cables, mechanical quick releases, breakaway connectionsdesigned to release at a specified pull force, integration intomechanical retention features on the user's clothing, and the like. Yetanother embodiment can include routing the cables in such a way as tominimize geometric differences between the user 101 and the cablelengths. One such embodiment in a dual knee configuration with a torsopower supply can be routing the cables along the user's lower torso toconnect the right side of a power supply bag with the left knee of theuser. Such a routing can allow the geometric differences in lengththroughout the user's normal range of motion.

One specific additional feature that can be a concern in someembodiments is the need for proper heat management of the exoskeletonsystem 100. As a result, there are a variety of features that can beintegrated specifically for the benefit of controlling heat. Onepreferred embodiment integrates exposed heat sinks to the environmentthat allow elements of the exoskeleton device 510 and/or pneumaticsystem 520 to dispel heat directly to the environment through unforcedcooling using ambient airflow. Another embodiment directs the ambientair through internal air channels in a backpack 155 or other housing toallow for internal cooling. Yet another embodiment can extend upon thiscapability by introducing scoops on a backpack 155 or other housing inan effort to allow air flow through the internal channels. Variousembodiments can include but are not limited to the following: exposedheat sinks that are directly connected to a high heat component; awater-cooled or fluid-cooled heat management system; forced air coolingthrough the introduction of a powered fan or blower; external shieldedheat sinks to protect them from direct contact by a user, and the like.

In some cases, it may be beneficial to integrate additional featuresinto the structure of the backpack 155 or other housing to provideadditional features to the exoskeleton system 100. One preferredembodiment is the integration of mechanical attachments to supportstorage of the leg actuator units 110 along with the exoskeleton device510 and/or pneumatic system 520 in a small package. Such an embodimentcan include a deployable pouch that can secure the leg actuator units110 against the backpack 155 along with mechanical clasps that hold theupper or lower arms 115, 120 of the actuator units 110 to the backpack155. Another embodiment is the inclusion of storage capacity into thebackpack 155 so the user 101 can hold additional items such as a waterbottle, food, personal electronics, and other personal items. Variousembodiments can include but are not limited to other additional featuressuch as the following: a warming pocket which is heated by hot airflowfrom the exoskeleton device 510 and/or pneumatic system 520; air scoopsto encourage additional airflow internal to the backpack 155; strappingto provide a closer fit of the backpack 155 on the user, waterproofstorage, temperature-regulated storage, and the like.

In a modular configuration, it may be required in some embodiments thatthe exoskeleton device 510 and/or pneumatic system 520 can be configuredto support the power, fluidic, sensing and control requirements andcapabilities of various potential configurations of the exoskeletonsystem. One preferred embodiment can include an exoskeleton device 510and/or pneumatic system 520 that can be tasked with powering a dual kneeconfiguration or a single knee configuration (i.e., with one or two legactuator units 110 on the user 101). Such an exoskeleton system 100 cansupport the requirements of both configurations and then appropriatelyconfigure power, fluidic, sensing and control based on a determinationor indication of a desired operating configuration. Various embodimentsexist to support an array of potential modular system configurations,such as multiple batteries, and the like.

In various embodiments, the exoskeleton device 100 can be operable toperform methods or portions of methods described in more detail below orin related applications incorporated herein by reference. For example,the memory 512 can include non-transitory computer readable instructions(e.g., software), which if executed by the processor 511, can cause theexoskeleton system 100 to perform methods or portions of methodsdescribed herein or in related applications incorporated herein byreference.

This software can embody various methods that interpret signals from thesensors 513 or other sources to determine how to best operate theexoskeleton system 100 to provide the desired benefit to the user. Thespecific embodiments described below should not be used to imply a limiton the sensors 513 that can be applied to such an exoskeleton system 100or the source of sensor data. While some example embodiments can requirespecific information to guide decisions, it does not create an explicitset of sensors 513 that an exoskeleton system 100 will require andfurther embodiments can include various suitable sets of sensors 513.Additionally, sensors 513 can be located at various suitable locationson an exoskeleton system 100 including as part of an exoskeleton device510, pneumatic system 520, one or more fluidic actuator 130, or thelike. Accordingly, the example illustration of FIG. 5 should not beconstrued to imply that sensors 513 are exclusively disposed at or partof an exoskeleton device 510 and such an illustration is merely providedfor purposes of simplicity and clarity.

One aspect of control software can be the operational control of legactuator units 110, exoskeleton device 510 and pneumatic system 520 toprovide the desired response. There can be various suitableresponsibilities of the operational control software. For example, asdiscussed in more detail below, one can be low-level control which canbe responsible for developing baseline feedback for operation of the legactuator units 110, exoskeleton device 510 and pneumatic system 520.Another can be intent recognition which can be responsible foridentifying the intended maneuvers of the user 101 based on data fromthe sensors 513 and causing the exoskeleton system 100 to operate basedon one or more identified intended maneuvers. A further example caninclude reference generation, which can include selecting the desiredtorques the exoskeleton system 100 should generate to best assist theuser 101. It should be noted that this example architecture fordelineating the responsibilities of the operational control software ismerely for descriptive purposes and in no way limits the wide variety ofsoftware approaches that can be deployed on further embodiments of anexoskeleton system 100.

One method implemented by control software can be for the low-levelcontrol and communication of the exoskeleton system 100. This can beaccomplished via a variety of methods as required by the specific jointand need of the user. In a preferred embodiment, the operational controlis configured to provide a desired torque by the leg actuator unit 110at the user's joint. In such a case, the exoskeleton system 100 cancreate low-level feedback to achieve a desired joint torque by the legactuator units 110 as a function of feedback from the sensors 513 of theexoskeleton system 100. For example, such a method can include obtainingsensor data from one or more sensors 513, determining whether a changein torque by the leg actuator unit 110 is necessary, and if so, causingthe pneumatic system 520 to change the fluid state of the leg actuatorunit 110 to achieve a target joint torque by the leg actuator unit 110.Various embodiments can include, but are not limited to, the following:current feedback; recorded behavior playback; position-based feedback;velocity-based feedback; feedforward responses; volume feedback whichcontrols a fluidic system 520 to inject a desired volume of fluid intoan actuator 130, and the like.

Another method implemented by operational control software can be forintent recognition of the user's intended behaviors. This portion of theoperational control software, in some embodiments, can indicate anyarray of allowable behaviors that the system 100 is configured toaccount for. In one preferred embodiment, the operational controlsoftware is configured to identify two specific states: Walking, and NotWalking. In such an embodiment, to complete intent recognition, theexoskeleton system 100 can use user input and/or sensor readings toidentify when it is safe, desirable or appropriate to provide assistiveactions for walking. For example, in some embodiments, intentrecognition can be based on input received via the user interface 515,which can include an input for Walking, and Not Walking. Accordingly, insome examples, the use interface can be configured for a binary inputconsisting of Walking, and Not Walking.

In some embodiments, a method of intent recognition can include theexoskeleton device 510 obtaining data from the sensors 513 anddetermining, based at least in part of the obtained data, whether thedata corresponds to a user state of Walking, and Not Walking. Where achange in state has been identified, the exoskeleton system 100 can bere-configured to operate in the current state. For example, theexoskeleton device 510 can determine that the user 101 is in a NotWalking state such as sitting and can configure the exoskeleton system100 to operate in a Not Walking configuration. For example, such a NotWalking configuration can, compared to a Walking configuration, providefor a wider range of motion; provide no torque or minimal torque to theleg actuation units 110; save power and fluid by minimizing processingand fluidic operations; cause the system to be alert for supporting awider variety of non-skiing motion, and the like.

The exoskeleton device 510 can monitor the activity of the user 101 andcan determine that the user is walking or is about to walk (e.g., basedon sensor data and/or user input), and can then configure theexoskeleton system 100 to operate in a Walking configuration. Forexample, such a Walking configuration, compared to a Not Walkingconfiguration, can allow for a more limited range of motion that wouldbe present during skiing (as opposed to motions during non-walking);provide for high or maximum performance by increasing the processing andfluidic response of the exoskeleton system 100 to support skiing; andthe like. When the user 101 finishes a walking session, is identified asresting, or the like, the exoskeleton system 100 can determine that theuser is no longer walking (e.g., based on sensor data and/or user input)and can then configure the exoskeleton system 100 to operate in the NotWalking configuration.

In some embodiments, there can be a plurality of Walking states, orWalking sub-states that can be determined by the exoskeleton system 100,including hard walking, moderate walking, light walking, downhill,uphill, jumping, recreational, sport, running, and the like (e.g., basedon sensor data and/or user input). Such states can be based on thedifficulty of the walking, ability of the user, terrain, weatherconditions, elevation, angle of the walking surface, desired performancelevel, power-saving, and the like. Accordingly, in various embodiments,the exoskeleton system 100 can adapt for various specific types ofwalking or movement based on a wide variety of factors.

Another method implemented by operational control software can be thedevelopment of desired referenced behaviors for the specific jointsproviding assistance. This portion of the control software can tietogether identified maneuvers with the level control. For example, whenthe exoskeleton system 100 identifies an intended user maneuver, thesoftware can generate reference behaviors that define the torques, orpositions desired by the actuators 130 in the leg actuation units 110.In one embodiment, the operational control software generates referencesto make the leg actuation units 110 simulate a mechanical spring at theknee 103 via the configuration actuator 130. The operational controlsoftware can generate torque references at the knee joints that are alinear function of the knee joint angle. In another embodiment, theoperational control software generates a volume reference to provide aconstant standard volume of air into a pneumatic actuator 130. This canallow the pneumatic actuator 130 to operate like a mechanical spring bymaintaining the constant volume of air in the actuator 130 regardless ofthe knee angle, which can be identified through feedback from one ormore sensors 513.

In another embodiment, a method implemented by the operational controlsoftware can include evaluating the balance of the user 101 whilewalking, moving, standing, or running and directing torque in such a wayto encourage the user 101 to remain balanced by directing kneeassistance to the leg 102 that is on the outside of the user's currentbalance profile. Accordingly, a method of operating an exoskeletonsystem 100 can include the exoskeleton device 510 obtaining sensor datafrom the sensors 510 indicating a balance profile of a user 101 based onthe configuration of left and right leg actuation units 110L, 110Rand/or environmental sensors such as position sensors, accelerometers,and the like. The method can further include determining a balanceprofile based on the obtained data, including an outside and inside leg,and then increasing torque to the actuation unit 110 associated with theleg 102 identified as the outside leg.

Various embodiments can use but are not limited to kinematic estimatesof posture, joint kinetic profile estimates, as well as observedestimates of body pose. Various other embodiments exist for methods ofcoordinating two legs 102 to generate torques including but not limitedto guiding torque to the most bent leg; guiding torque based on the meanamount of knee angle across both legs; scaling the torque as a functionof speed or acceleration; and the like. It should also be noted that yetanother embodiment can include a combination of various individualreference generation methods in a variety of matters which include butare not limited to a linear combination, a maneuver specificcombination, or a non-linear combination.

In another embodiment, an operational control method can blend twoprimary reference generation techniques: one reference focused on staticassistance and one reference focused on leading the user 101 into theirupcoming behavior. In some examples, the user 101 can select how muchpredictive assistance is desired while using the exoskeleton system 100.For example, by a user 101 indicating a large amount of predictiveassistance, the exoskeleton system 100 can be configured to be veryresponsive and may be well configured for a skilled operator on achallenging terrain. The user 101 could also indicate a desire for avery low amount of predictive assistance, which can result in slowersystem performance, which may be better tailored towards a learning useror less challenging terrain.

Various embodiments can incorporate user intent in a variety of mannersand the example embodiments presented above should not be interpreted aslimiting in any way. For example, method of determining and operating anexoskeleton system 100 can include systems and method of U.S. patentapplication Ser. No. 15/887,866, filed Feb. 2, 2018 entitled “SYSTEM ANDMETHOD FOR USER INTENT RECOGNITION,” having attorney docket number0110496-003US0, which is incorporated herein by reference. Also, variousembodiments can use user intent in a variety of manners including as acontinuous unit, or as a discrete setting with only a few indicatedvalues.

At times it can be beneficial for operational control software tomanipulate its control to account for a secondary or additionalobjective in order to maximize device performance or user experience. Inone embodiment, the exoskeleton system 100 can provide anelevation-aware control over a central compressor or other components ofa pneumatic system 520 to account for the changing density of air atdifferent elevations. For example, operational control software canidentify that the system is operating at a higher elevation based ondata from sensors 513, or the like, and provide more current to thecompressor in order to maintain electrical power consumed by thecompressor. Accordingly, a method of operating a pneumatic exoskeletonsystem 100 can include obtaining data indicating air density where thepneumatic exoskeleton system 100 is operating (e.g., elevation data),determining optimal operating parameters of the pneumatic system 520based on the obtained data, and configuring operation based on thedetermined optimal operating parameters. In further embodiments,operation of a pneumatic exoskeleton system 100 such as operatingvolumes can be tuned based on environmental temperature, which mayaffect air volumes.

In another embodiment, the exoskeleton system 100 can monitor theambient audible noise levels and vary the control behavior of theexoskeleton system 100 to reduce the noise profile of the system. Forexample, when a user 101 is in a quiet public place or quietly enjoyinga location alone or with others, noise associated with actuation of theleg actuation units 110 can be undesirable (e.g., noise of running acompressor or inflating or deflating actuators 130). Accordingly, insome embodiments, the sensors 513 can include a microphone that detectsambient noise levels and can configure the exoskeleton system 100 tooperate in a quiet mode when ambient noise volume is below a certainthreshold. Such a quiet mode can configure elements of a pneumaticsystem 520 or actuators 130 to operate more quietly, or can delay orreduce frequency of noise made by such elements.

In the case of a modular system, it can be desirable in variousembodiments for operational control software to operate differentlybased on the number of leg actuation units 110 operational within theexoskeleton system 100. For example, in some embodiments, a modulardual-knee exoskeleton system 100 (see e.g., FIGS. 1 and 2) can alsooperate in a single knee configuration where only one of two legactuation units 110 are being worn by a user 101 (see e.g., FIGS. 3 and4) and the exoskeleton system 100 can generate references differentlywhen in a two-leg configuration compared to a single leg configuration.Such an embodiment can use a coordinated control approach to generatereferences where the exoskeleton system 100 is using inputs from bothleg actuation units 110 to determine the desired operation. However in asingle-leg configuration, the available sensor information may havechanged, so in various embodiments the exoskeleton system 100 canimplement a different control method. In various embodiments this can bedone to maximize the performance of the exoskeleton system 100 for thegiven configuration or account for differences in available sensorinformation based on there being one or two leg actuation units 110operating in the exoskeleton system 100.

Accordingly, a method of operating an exoskeleton system 100 can includea startup sequence where a determination is made by the exoskeletondevice 510 whether one or two leg actuation units 110 are operating inthe exoskeleton system 100; determining a control method based on thenumber of actuation units 110 that are operating in the exoskeletonsystem 100; and implementing and operating the exoskeleton system 100with the selected control method. A further method operating anexoskeleton system 100 can include monitoring by the exoskeleton device510 of actuation units 110 that are operating in the exoskeleton system100, determining a change in the number of actuation units 110 operatingin the exoskeleton system 100, and then determining and changing thecontrol method based on the new number of actuation units 110 that areoperating in the exoskeleton system 100.

For example, the exoskeleton system 100 can be operating with twoactuation units 110 and with a first control method. The user 101 candisengage one of the actuation units 110, and the exoskeleton device 510can identify the loss of one of the actuation units 110 and theexoskeleton device 510 can determine and implement a new second controlmethod to accommodate loss of one of the actuation units 110. In someexamples, adapting to the number of active actuation units 110 can bebeneficial where one of the actuation units 110 is damaged ordisconnected during use and the exoskeleton system 100 is able to adaptautomatically so the user 101 can still continue working or movinguninterrupted despite the exoskeleton system 100 only having a singleactive actuation unit 110.

In various embodiments, operational control software can adapt a controlmethod where user needs are different between individual actuation units110 or legs 102. In such an embodiment, it can be beneficial for theexoskeleton system 100 to change the torque references generated in eachactuation unit 110 to tailor the experience for the user 101. Oneexample is of a dual knee exoskeleton system 100 (see e.g., FIG. 1)where a user 101 has significant weakness issues in a single leg 102,but only minor weakness issues in the other leg 102. In this example,the exoskeleton system 100 can be configured to scale down the outputtorques on the less-affected limb compared to the more-affected limb tobest meet the needs of the user 101.

Such a configuration based on differential limb strength can be doneautomatically by the exoskeleton system 100 and/or can be configured viaa user interface 516, or the like. For example, in some embodiments, theuser 101 can perform a calibration test while using the exoskeletonsystem 100, which can test relative strength or weakness in the legs 102of the user 101 and configure the exoskeleton system 100 based onidentified strength or weakness in the legs 102. Such a test canidentify general strength or weakness of legs 102 or can identifystrength or weakness of specific muscles or muscle groups such as thequadriceps, calves, hamstrings, gluteus, gastrocnemius; femoris,sartorius, soleus, and the like.

Another aspect of a method for operating an exoskeleton system 100 caninclude control software that monitors the exoskeleton system 100. Amonitoring aspect of such software can, in some examples, focus onmonitoring the state of the exoskeleton system 100 and the user 101throughout normal operation in an effort to provide the exoskeletonsystem 100 with situational awareness and understanding of sensorinformation in order to drive user understanding and device performance.One aspect of such monitoring software can be to monitor the state ofthe exoskeleton system 100 in order to provide device understanding toachieve a desired performance capability. A portion of this can be thedevelopment of a system body pose estimate. In one embodiment, theexoskeleton device 510 uses the onboard sensors 513 to develop areal-time understanding of the user's pose. In other words, data fromsensors 513 can be used to determine the configuration of the actuationunits 110, which along with other sensor data can in turn be used toinfer a user pose or body configuration estimate of the user 101 wearingthe actuation units 110.

At times, and in some embodiments, it can be unrealistic or impossiblefor the exoskeleton system 100 to directly sense all important aspectsof the system pose due to the sensing modalities not existing or theirinability to be practically integrated into the hardware. As a result,the exoskeleton system 100 in some examples can rely on a fusedunderstanding of the sensor information around an underlying model ofthe user's body and the exoskeleton system 100 the user is wearing. Inone embodiment of a dual leg knee assistance exoskeleton system 100, theexoskeleton device 510 can use an underlying model of the user's lowerextremity and torso body segments to enforce a relational constraintbetween the otherwise disconnected sensors 513. Such a model can allowthe exoskeleton system 100 to understand the constrained motion of thetwo legs 102 in that they are mechanically connected through the user'skinematic chain created by the body. This approach can be used to ensurethat the estimates for knee orientation are properly constrained andbiomechanically valid. In various embodiments, the exoskeleton system100 can include sensors 513 embedded in the exoskeleton device 510and/or pneumatic system 520 to provide a fuller picture of the systemposture. In yet another embodiment, the exoskeleton system 100 caninclude logical constraints that are unique to the application in aneffort to provide additional constraints on the operation of the poseestimation. This can be desirable, in some embodiments, in conditionswhere ground truth information is unavailable such as highly dynamicactions, where the exoskeleton system 100 is denied an external GPSsignal, or the earth's magnetic field is distorted.

In some embodiments, changes in configuration of the exoskeleton system100 based location and/or location attributes can be performedautomatically and/or with input from the user 101. For example, in someembodiments, the exoskeleton system 100 can provide one or moresuggestions for a change in configuration based on location and/orlocation attributes and the user 101 can choose to accept suchsuggestions. In further embodiments, some or all configurations of theexoskeleton system 100 based location and/or location attributes canoccur automatically without user interaction.

Various embodiments can include the collection and storage of data fromthe exoskeleton system 100 throughout operation. In one embodiment, thiscan include the live streaming of the data collected on the exoskeletondevice 510 to a cloud storage location via the communication unit(s) 514through an available wireless communication protocol or storage of suchdata on the memory 512 of the exoskeleton device 510, which may then beuploaded to another location via the communication unit(s) 514. Forexample, when the exoskeleton system 100 obtains a network connection,recorded data can be uploaded to the cloud at a communication rate thatis supported by the available data connection. Various embodiments caninclude variations of this, but the use of monitoring software tocollect and store data about the exoskeleton system 100 locally and/orremotely for retrieval at a later time for an exoskeleton system 100such as this can be included in various embodiments.

In some embodiments, once such data has been recorded, it can bedesirable to use the data for a variety of different applications. Onesuch application can be the use of the data to develop further oversightfunctions on the exoskeleton system 100 in an effort to identify devicesystem issues that are of note. One embodiment can be the use of thedata to identify a specific exoskeleton system 100 or leg actuator unit110 among a plurality, whose performance has varied significantly over avariety of uses. Another use of the data can be to provide it back tothe user 101 to gain a better understanding of how they ski. Oneembodiment of this can be providing the data back to the user 101through a mobile application that can allow the user 101 to review theiruse on a mobile device. Yet another use of such device data can be tosynchronize playback of data with an external data stream to provideadditional context. One embodiment is a system that incorporates the GPSdata from a companion smartphone with the data stored natively on thedevice. Another embodiment can include the time synchronization ofrecorded video with the data stored that was obtained from the device100. Various embodiments can use these methods for immediate use of databy the user to evaluate their own performance, for later retrieval bythe user to understand behavior from the past, for users to compare withother users in-person or through an online profile, by developers tofurther the development of the system, and the like.

Another aspect of a method of operating an exoskeleton system 100 caninclude monitoring software configured for identifying user-specifictraits. For example, the exoskeleton system 100 can provide an awarenessof how a specific skier 101 operates in the exoskeleton system 100 andover time can develop a profile of the user's specific traits in aneffort to maximize device performance for that user. One embodiment caninclude the exoskeleton system 100 identifying a user-specific use typein an effort to identify the use style or skill level of the specificuser. Through an evaluation of the user form and stability duringvarious actions (e.g., via analysis of data obtained from the sensors513 or the like), the exoskeleton device 510 in some examples canidentify if the user is highly skilled, novice, or beginner. Thisunderstanding of skill level or style can allow the exoskeleton system100 to better tailor control references to the specific user.

In further embodiments, the exoskeleton system 100 can also useindividualized information about a given user to build a profile of theuser's biomechanic response to the exoskeleton system 100. Oneembodiment can include the exoskeleton system 100 collecting dataregarding the user to develop an estimate of the individual user's kneestrain in an effort to assist the user with understanding the burden theuser has placed on his legs 102 throughout use. This can allow theexoskeleton system 100 to alert a user if the user has reached ahistorically significant amount of knee strain to alert the user that hemay want to stop to spare himself potential pain or discomfort.

Another embodiment of individualized biomechanic response can be thesystem collecting data regarding the user to develop an individualizedsystem model for the specific user. In such an embodiment theindividualized model can be developed through a system ID(identification) method that evaluates the system performance with anunderlying system model and can identify the best model parameters tofit the specific user. The system ID in such an embodiment can operateto estimate segment lengths and masses (e.g., of legs 102 or portions ofthe legs 102) to better define a dynamic user model. In anotherembodiment, these individualized model parameters can be used to deliveruser specific control responses as a function of the user's specificmasses and segment lengths. In some examples of a dynamic model, thiscan help significantly with the device's ability to account for dynamicforces during highly challenging activities.

In various embodiments, the exoskeleton system 100 can provide forvarious types of user interaction. For example, such interaction caninclude input from the user 101 as needed into the exoskeleton system100 and the exoskeleton system 100 providing feedback to the user 101 toindicate changes in operation of the exoskeleton system 100, status ofthe exoskeleton system 100, and the like. As discussed herein, userinput and/or output to the user can be provided via one or more userinterface 515 of the exoskeleton device 510 or can include various otherinterfaces or devices such as a smartphone user device. Such one or moreuser interfaces 515 or devices can be located in various suitablelocations such as on a backpack 155 (see e.g., FIG. 1), the pneumaticsystem 520, leg actuation units 110, or the like.

The exoskeleton system 100 can be configured to obtain intent from theuser 101. For example, this can be accomplished through a variety ofinput devices that are either integrated directly with the othercomponents of the exoskeleton system 100 (e.g., one or more userinterface 515), or external and operably connected with the exoskeletonsystem 100 (e.g., a smartphone, wearable device, remote server, or thelike). In one embodiment, a user interface 515 can comprise a buttonthat is integrated directly into one or both of the leg actuation units110 of the exoskeleton system 100. This single button can allow the user101 to indicate a variety of inputs. In another embodiment, a userinterface 515 can be configured to be provided through a torso-mountedlapel input device that is integrated with the exoskeleton device 510and/or pneumatic system 520 of the exoskeleton system 100. In oneexample, such a user interface 515 can comprise a button that has adedicated enable and disable functionality; a selection indicatordedicated to the user's desired power level (e.g., an amount or range offorce applied by the leg actuator units 110); and a selector switch thatcan be dedicated to the amount of predictive intent to integrate intothe control of the exoskeleton system 100. Such an embodiment of a userinterface 515 can use a series of functionally locked buttons to providethe user 101 with a set of understood indicators that may be requiredfor normal operation in some examples. Yet another embodiment caninclude a mobile device that is connected to the exoskeleton system 100via a Bluetooth connection or other suitable wired or wirelessconnection. Use of a mobile device or smartphone as a user interface 515can allow the user a far greater amount of input to the device due tothe flexibility of the input method. Various embodiments can use theoptions listed above or combinations and variants thereof, but are in noway limited to the explicitly stated combinations of input methods anditems.

The one or more user interface 515 can provide information to the user101 to allow the user to appropriately use and operate the exoskeletonsystem 100. Such feedback can be in a variety of visual, haptic and/oraudio methods including, but not limited to, feedback mechanismsintegrated directly on one or both of the actuation units 110; feedbackthrough operation of the actuation units 110; feedback through externalitems not integrated with the exoskeleton system 100 (e.g., a mobiledevice); and the like. Some embodiments can include integration offeedback lights in the actuation units 110, of the exoskeleton system100. In one such embodiment, five multi-color lights are integrated intothe knee joint 125 or other suitable location such that the user 101 cansee the lights. These lights can be used to provide feedback of systemerrors, device power, successful operation of the device, and the like.In another embodiment, the exoskeleton system 100 can provide controlledfeedback to the user to indicate specific pieces of information. In suchembodiments, the exoskeleton system 100 can pulse the joint torque onone or both of the leg actuation units 110 to the maximum allowed torquewhen the user changes the maximum allowable user-desired torque, whichcan provide a haptic indicator of the torque settings. Anotherembodiment can use an external device such as a mobile device where theexoskeleton system 100 can provide alert notifications for deviceinformation such as operational errors, setting status, power status,and the like. Types of feedback can include, but are not limited to,lights, sounds, vibrations, notifications, and operational forcesintegrated in a variety of locations that the user 101 may be expectedto interact with including the actuation units 110, pneumatic system520, backpack 155, mobile devices, or other suitable methods ofinteractions such as a web interface, SMS text or email.

The communication unit 514 can include hardware and/or software thatallows the exoskeleton system 100 to communicate with other devices,including a user device, a classification server, other exoskeletonsystems 100, or the like, directly or via a network. For example, theexoskeleton system 100 can be configured to connect with a user device,which can be used to control the exoskeleton system 100, receiveperformance data from the exoskeleton system 100, facilitate updates tothe exoskeleton system, and the like. Such communication can be wiredand/or wireless communication.

In some embodiments, the sensors 513 can include any suitable type ofsensor, and the sensors 513 can be located at a central location or canbe distributed about the exoskeleton system 100. For example, in someembodiments, the exoskeleton system 100 can comprise a plurality ofaccelerometers, force sensors, position sensors, and the like, atvarious suitable positions, including at the arms 115, 120, joint 125,actuators 130 or any other location.

Accordingly, in some examples, sensor data can correspond to a physicalstate of one or more actuators 130, a physical state of a portion of theexoskeleton system 100, a physical state of the exoskeleton system 100generally, and the like. In some embodiments, the exoskeleton system 100can include a global positioning system (GPS), camera, range sensingsystem, environmental sensors, elevation sensor, microphone,thermometer, or the like. In some embodiments, the exoskeleton system100 can obtain sensor data from a user device such as a smartphone, orthe like.

In some cases, it can be beneficial for the exoskeleton system 100 togenerate or augment an understanding of a user 101 wearing theexoskeleton device 100, of the environment and/or operation of theexoskeleton system 100 through integrating various suitable sensors 515into the exoskeleton system 100. One embodiment can include sensors 515to measure and track biological indicators to observe various suitableaspects of user 101 (e.g., corresponding to fatigue and/or body vitalfunctions) such as, body temperature, heart rate, respiratory rate,blood pressure, blood oxygenation saturation, expired CO₂, blood glucoselevel, gait speed, sweat rate, and the like.

In some embodiments, the exoskeleton system 100 can take advantage ofthe relatively close and reliable connectivity of such sensors 515 tothe body of the user 101 to record system vitals and store them in anaccessible format (e.g., at the exoskeleton device, a remote device, aremote server, or the like). Another embodiment can includeenvironmental sensors 515 that can continuously or periodically measurethe environment around the exoskeleton system 100 for variousenvironmental conditions such as temperature, humidity, light level,barometric pressure, radioactivity, sound level, toxins, contaminants,or the like. In some examples, various sensors 515 may not be requiredfor operation of the exoskeleton system 100 or directly used byoperational control software, but can be stored for reporting to theuser 101 (e.g., via an interface 515) or sending to a remote device, aremote server, or the like.

The pneumatic system 520 can comprise any suitable device or system thatis operable to inflate and/or deflate the actuators 130 individually oras a group. For example, in one embodiment, the pneumatic system cancomprise a diaphragm compressor as disclosed in related patentapplication Ser. No. 14/577,817 filed Dec. 19, 2014 or a pneumatic powertransmission as discussed herein.

Turning to FIGS. 6-10, another embodiment of an exoskeleton system 100is illustrated. In this example embodiment, the exoskeleton system 100includes a single right leg actuator unit 110; however, it should beclear that this example embodiment can be extended to an exoskeletonsystem 100 having both a left and right actuator unit 110L, 110R or onlya left actuator unit 110L. Accordingly the example of FIGS. 6-10 shouldnot be construed as limiting, and in further embodiments, any suitableelements can be present in a suitable plurality, absent, interchangedwith elements of other embodiments (e.g., FIGS. 1-4), or the like.

As shown in FIGS. 6-10, the leg actuator unit 110 can include an upperarm 115 and a lower arm 120 that are rotatably coupled via a joint 125.A bellows actuator 130 extends between the upper arm 115 and lower arm120. One or more sets of pneumatic lines 145 can be coupled to thebellows actuator 130 to introduce and/or remove fluid from the bellowsactuator 130 to cause the bellows actuator 130 to expand and contractand to stiffen and soften, as discussed herein. The pneumatic lines 145can comprise a line coupling 146 that can be engaged and disengaged tooperably connect or disconnect the actuator unit 110 from theexoskeleton system 100. A backpack 155 can be worn by the user 101 (seeFIGS. 6, 8 and 9) and can hold various components of the exoskeletonsystem 100 such as a fluid source, control system, a power source,exoskeleton device, pneumatic system, and the like as discussed herein.

As shown in FIGS. 6-9, the leg actuator unit 110 can be coupled aboutthe right leg of the user 101 with the joint 125 positioned at the rightknee 103R of the user 101 (see FIGS. 1-3 for labeling of body parts ofthe user 101), with the upper arm 115 of the leg actuator unit 110Rbeing coupled about the right upper-leg portion 104R of the user 101 viaone or more couplers 150 (e.g., straps that surround the legs 102). Thelower arm 120 of the leg actuator unit 110 can be coupled about theright lower-leg portion 105R of the user 101 via one or more couplers150.

The upper and lower arms 115, 120 of a leg actuator unit 110 can becoupled about the leg 102 of a user 101 in various suitable ways. Forexample, FIGS. 6-9 illustrate an example where the upper and lower arms115, 120 and joint 125 of the leg actuator unit 110 are coupled alonglateral faces (sides) of the top and bottom portions 104, 105 of the leg102. As shown in the example of FIGS. 6-9, the upper arm 115 can becoupled to the upper-leg portion 104 of a leg 102 above the knee 103 viaone coupler 150 and the lower arm 120 can be coupled to the lower-legportion 105 of a leg 102 below the knee 103 via two couplers 150.

Specifically, upper arm 115 can be coupled to the upper-leg portion 104of the leg 102 above the knee 103 via a first upper-leg coupler 150A.The first upper-leg coupler 150A can be associated with a rigidupper-leg brace 615 disposed on and engaging a lateral side of theupper-leg portion 104 of the leg 102, with a strap of the firstupper-leg coupler 150A extending around the upper-leg portion 104 of theleg 102. The upper arm 115 can be coupled to the rigid upper-leg brace615 on a lateral side of the upper-leg portion 104 of the leg 102, whichcan transfer force generated by the upper arm 115 to the upper-legportion 104 of the leg 102.

The lower arm 120 can be coupled to the lower-leg portion 105 of a leg102 below the knee 103 via a second set of couplers 650 that includesfirst and second lower-leg couplers 150C, 150D. The first and secondlower-leg couplers 150C, 150D can be associated with a rigid lower-legbrace 620 disposed on and engaging a lateral side of the lower-legportion 105 of the leg 102. The lower arm 120 can be coupled to therigid lower-leg brace 620 on a lateral side of the lower-leg portion 105of the leg 102, which can transfer force generated by the lower arm 120to the lower-leg portion 105 of the leg 102. The rigid lower-leg brace620 can extend downward from a coupling with the lower arm 120 at alateral position on the lower-leg portion 105 of the leg 102, with aportion of the rigid lower-leg brace 620 curving toward the posterior(back) of the lower-leg portion 105 to attachments 622, 624 that coupleone or more portions of the first and second lower-leg couplers 150C,150D to the rigid lower-leg brace 620.

The first lower-leg coupler 150C can include a calf-coupling assembly630 that includes a calf brace 632 that is coupled to the rigidlower-leg brace 620 via a first, second and third calf strap 634, 636,638. For example, as shown in the example of FIGS. 6 and 7, the firstand second calf straps 634, 636 can extend horizontally from opposinglateral sides of an upper portion of the rigid lower-leg brace 620 froman internal face of the rigid lower-leg brace 620. The third calf strap638 can extend vertically from a lower posterior portion of the rigidlower-leg brace 620 from an internal face of the rigid lower-leg brace620 where the third calf strap 638 is coupled to the rigid lower-legbrace 620 via a first set of one or more attachments 622. In variousembodiments, the calf brace 632 can be a rigid or flexible element andcan comprise materials such as a fabric, plastic, carbon-fiber, or thelike.

The calf straps 634, 636, 638 can be configured in various suitable waysand can include various suitable mechanisms that allow the calf straps634, 636, 638 to be tightened, loosened, extended, shortened, or thelike. For example, in some embodiments, the first and second calf straps634, 636 comprise hook and loop tape (e.g., Velcro) that allows thesecond calf straps 634, 636 to be tightened, loosened, extended,shortened, or the like. In some embodiments, the third calf strap 638can comprise a strap cinch, or the like, that allows the third calfstrap 638 to be tightened, loosened, extended, shortened, or the like.

The second lower-leg coupler 150D can comprise an ankle-couplingassembly 640 that includes a cuff 642 that extends around and surroundsthe lower-leg portion 105 above the ankle of the user 101 and held viaan ankle strap 644. The cuff 642 can be coupled to the rigid lower-legbrace 620 via one or more coupling tabs 646 that extend vertically fromthe cuff 642, with the one or more coupling tabs 646 coupled to therigid lower-leg brace 620 via a second set of one or more attachments624 on an internal face of the rigid lower-leg brace 620. The anklestrap 644 can include various suitable elements that allow the anklestrap to be tightened, loosened, extended, shortened, or the like (e.g.,hook and loop tape, strap cinch, or the like).

In various embodiments, the rigid upper-leg and lower-leg braces 615,620 can be made of various suitable materials such as a plastic,carbon-fiber, metal, wood, or the like. As discussed herein, in someembodiments the upper-leg and/or lower-leg braces 615, 620 can be formedto match the contours of the legs 102 of the user 101, which can bedesirable for increasing comfort for the user 101 maximizing surfacearea of the upper-leg and/or lower-leg braces 615, 620 engaging the legs102 of the user 101, and the like. In some examples, the upper-legand/or lower-leg braces 615, 620 can be formed specifically for a givenuser 101, which can include molding to user body parts, scanning theuser's body and generating upper-leg and/or lower-leg braces 615, 620from such scan data, and the like.

As discussed herein, various embodiments of an exoskeleton system 100can be configured to operate modularly. For example, the exoskeletonsystem 100 can have a left and right leg actuator unit 110L, 110R andoperate in a dual-leg configuration. However, in some embodiments, theleft leg actuator unit 110L can be removed to generate a configurationas shown in FIG. 11 where the exoskeleton system 100 only includes aright actuator unit 110R and operates in a single-leg rightconfiguration. Alternatively, the right leg actuator unit 110R can beremoved to generate a configuration as shown in FIG. 12 where theexoskeleton system 100 only includes a left actuator unit 110L andoperates in a single-leg left configuration. In various embodiments, anexoskeleton system 100 operating in a single-leg configuration such asshown in FIGS. 11 and 12, can then have a leg actuation unit coupled tothe exoskeleton system 100 on the opposing body side leg such that theexoskeleton system 100 operates in a dual-leg configuration as shown inFIG. 5.

In the example case of a modular exoskeleton system 100 where one ormore leg actuation units 110 can be coupled to and actuated by theexoskeleton system 100, it can be desirable in some embodiments foroperational control software executed by an exoskeleton device 510 tooperate based on a determination of a number and identity of one or moreactuation units 110 coupled with and operational within the exoskeletonsystem 100. In one embodiment of a modular dual-knee exoskeleton system100 that can also operate in a single knee configuration (e.g., a systemthat can operate with one or both of a left and right leg actuation unit110L, 110R), operational control software executed by an exoskeletondevice 510 can generate references for the exoskeleton system 100differently when in a two-leg configuration and when in a single-legconfiguration. Specifically, such an embodiment may use a coordinatedcontrol approach to generate references where the exoskeleton system 100is using inputs from both legs to determine the desired operation;however, in a single-leg configuration, the available sensor informationcan change (e.g., sensors 513 associated with and/or disposed on asecond actuation unit 110 may be absent or disabled) so the exoskeletonsystem 100 can implement a different strategy based on the availablesensor data. In various embodiments, this can be done to maximize theperformance of the exoskeleton system 100 for the given configuration orto account for variations in available sensor information.

Turning to FIG. 13, one example method 1300 of operating a modularexoskeleton system 100 is illustrated. The method 1300 begins at 1310where an exoskeleton device 510 monitors for actuator units 110 beingcoupled to or removed from the modular exoskeleton system 100. Forexample, as discussed herein, in various embodiments one or moreactuator units 110 can be operably coupled to an exoskeleton system 100via one or more lines 145, which can include fluidic lines,communication lines, sensor lines, power lines, and the like. Theexoskeleton device 510, in some embodiments, can determine whether oneor more actuator units 110 are operably coupled to the exoskeletonsystem 100 based on data, information, or a status associated with suchlines, based on user input, wireless communication (e.g., Bluetooth,NFC, RFID), or the like. In some embodiments, the exoskeleton device 510can determine whether one or more actuator units 110 are operablycoupled to the exoskeleton system 100 based on data, information or astatus communicated wirelessly (e.g., through Bluetooth, ANT, RFID, awireless network, etc.) between the actuator unit 110 and theexoskeleton system 100. Accordingly, it should be clear that variousembodiments of an exoskeleton system 100 can have any suitable physical,wired and/or wireless operable coupling between one or more actuatorunits 110 and an exoskeleton device 510, with some embodiments includingno physical or wired operable couplings between an actuator unit 110 andan exoskeleton device 510, with the actuator unit 110 being controlledwirelessly and having an independent power source and fluid source thatdoes not require a physical coupling to an exoskeleton device 510.

In some examples, a line coupling 146 (see FIG. 7) being coupled orde-coupled can be used to determine whether a given actuator unit 110 isoperably coupled to the exoskeleton system 100 (e.g., via a switch, ordetection of an operable coupling generated by a connection of a linecoupling 146 such as an operable coupling of fluidic lines,communication lines, sensor lines, power lines, and the like).

Returning to the example method 1300 of operating a modular exoskeletonsystem 100 of FIG. 13, at 1320, the exoskeleton device 510 can determinethat one or more new actuator unit 110 has been coupled with theexoskeleton system 100, and at 1330, the exoskeleton device 510 candetermine a location where the new actuator unit 110 is coupled on thebody of the user 101. In some examples, the exoskeleton device 510 canbe configured to determine an identity of an actuator unit 110 such as aserial number, MAC address, model number, or the like, based on aoperable connection with the actuator unit 110, user input, or the like.

In some examples, the exoskeleton device 510 can be configured todetermine a location where a given actuator unit 110 is coupled on thebody of a user (e.g., left leg, right leg, left arm, right arm, torso,neck, and the like), based on a determined identity of the actuator unit110, based on a coupling slot that the actuator unit 110 is plugged into(e.g., a left-leg or right-leg line coupling 146), based on userselection, based on wireless communication between the exoskeletondevice 510 and the actuator unit 110, or the like. For example, anidentifier obtained by the exoskeleton device 510 corresponding to aleft leg actuator unit 110L can be associated with information thatindicates that the left leg actuator unit 110L is specificallyconfigured for being coupled to the left leg 102L of the user 101 and/ornot the right leg 102L of the user 101. Such an identifier can be usedto determine, at least implicitly, that the left leg actuator unit 110Lis coupled to the left leg 102L of the user 101 and/or that the left legactuator unit 110L is not coupled to the right leg 102L of the user 101or not coupled to another body portion or joint such as an arm, elbow,wrist, shoulder, or the like. Additionally, it should be clear that adetermination that an actuation unit 110 is coupled to a given limb,body joint, or the like, may include an implicit determination of such acoupling and that such a determination may not actually include adetermination or confirmation of a suitable physical coupling to a givenlimb of a user.

Also, while some examples illustrated herein show one or more actuatorunits 110 that consist of a single actuator 130, further embodiments caninclude actuator units 110 that comprise a plurality actuators anddetermining the identity and/or locations of an actuator unit 110 caninclude determining a number of actuators 130 associated with a givenactuator unit 110 and the location of such actuator units 110 and/ortheir associated actuators 130 on the body of a user 101. For example,in some embodiments, the identity of an actuator unit 110 can beassociated with the number of actuators 130 of the actuator unit 110,the location of one or more actuators 130, body joint(s) and/orlocation(s) that such actuators are associated with, a kinematic modelof an actuator unit 110, or the like.

Returning to the example method 1300 of operating a modular exoskeletonsystem 100, the exoskeleton device 510, at 1340, can determine a newoperating configuration, and at 1350, can set the new operatingconfiguration based on a current set of actuator units 110 coupled tothe exoskeleton system 100. For example, where a determination is madethat a right and left leg actuator 110R, 110L with actuators 130R, 130Lon respective knees 103R, 103L are coupled to the exoskeleton system 100(e.g., as shown in FIG. 5), the exoskeleton device 510 can determine andset a dual-knee operating configuration.

However, if a determination is made that only a right leg actuator 110R,with only an actuator 130R associated with the right knee 103R, iscoupled to the exoskeleton system 100 (e.g., as shown in FIG. 11), theexoskeleton device 510 can determine and set a single-right-kneeoperating configuration. However, if a determination is made that only aleft leg actuator 110L, with only an actuator 130L associated with theleft knee 103L, is coupled to the exoskeleton system 100 (e.g., as shownin FIG. 12), the exoskeleton device 510 can determine and set asingle-left-knee operating configuration.

Returning to the example method 1300 of operating a modular exoskeletonsystem 100, at 1360, the exoskeleton device 510 can determine that anactuator unit 110 has been removed from the exoskeleton system 100 andthe exoskeleton device 510 can then determine and set an operatingconfiguration at 1340 and 1350. For example, if an exoskeleton isoperating in a dual-knee operating configuration with a left and rightleg actuator 110L, 110R (e.g., as shown in FIG. 5) and then the left legactuator 110L is removed (e.g., generating the configuration of FIG.11), the exoskeleton device 510 can identify the removal of the left legactuator 110L and switch to operating in a single-right-knee operatingconfiguration. It should be made clear that the removal of an actuatorunit 110 can be caused by, but is not limited to, a physicaldisconnection from the exoskeleton system 100 through a disconnection ofa line coupling 146 or a wireless connection between the actuator unit110 and the exoskeleton system 100, a removal by user selection, amalfunction of an actuator unit 110 rendering it inoperable or partiallyinoperable, and the like.

In various embodiments, determining and setting an operatingconfiguration after removal of one or more actuation unit 110 can bedone in various suitable ways, including determine the identity ofactuator units 110 (if any) coupled to the exoskeleton system 100;determining a new configuration by identifying one or more actuationunits 110 that have been removed and modifying a current configurationto a new configuration based on the identity the one or more removedactuator unit 110; or the like. Also, in some embodiments, adetermination can be made that no actuation units 110 are operablycoupled to the exoskeleton system 100 or that a set or a partial set ofactuation units 110 operably coupled to the exoskeleton system 100 is aset or a partial set that is not allowed or not a set or a partial setof actuation units 110 that there is a suitable operating configurationfor. For example, if a user accidently couples two left leg actuatorunits 110L to the exoskeleton system 100, the exoskeleton system 100 canidentity this set of left leg actuator units 110L as being not allowedor not a set of actuation units 110 that there is a suitable operatingconfiguration for, and an error message can be presented via a userinterface 515 or only one of the left leg actuator units 110L can bedetermined as coupled to the device 510 leading to a singleleft-knee-operating configuration, or the like.

While various examples herein relate to embodiments that can include oneor two leg actuator units 110L, 110R with actuators 130L, 130R at theknees 103L, 103R, it should be clear that the methods discuss herein canbe used in embodiments with any suitable plurality of actuator units 110on any suitable portion of the body with one or more actuators 130configured to actuate any suitable body joint of a user as discussedherein. For example, one example can include a modular system with fouractuator units 110 configured to actuate the knees and elbows of a user101 with each of the four actuator units 110 having a single actuator130 configured to actuate a respective joint of the user 101.Accordingly, the example embodiments herein should not be construed asbeing limiting.

Another novel consideration in some examples of operational controlsoftware is if the user's needs are different between individual jointsor legs. In such a scenario, it may be beneficial for the exoskeletonsystem 100 to change the torque references generated for each legactuator unit 110L, 110R to tailor the experience for the user. Oneexample embodiment is that of a dual-knee exoskeleton configurationwhere a user has significant pain issues in a single leg, but not in theother leg. In such a case, the exoskeleton system 100 can include theability for the exoskeleton system 100 to scale the output torques onthe unaffected limb to best meet the needs of the user. In someexamples, determining an operating configuration in a modularexoskeleton system 100 can include determining a set of one or moreactuator units 110 operably coupled to the exoskeleton system 100 anddetermining settings of the one or more actuation units 110 based on thelocation of the actuators and different user needs between one or moreindividual body joints of the user 101.

Accordingly, in some embodiments, generating references can be based ondifferential needs of different legs of a user, which in some examplescan include generating references for a left and right actuator unit110L, 110R and scaling the references for one of the legs. For example,where a user has a weak left leg 102L and a fully capable right leg102R, the exoskeleton system 100 can generate references for a left andright actuator unit 110L, 110R (e.g., via one or both of methods 1100,1101), and can reduce the references for the right leg actuator unit110R by 50% so that the weaker left leg 102L receives 100% referencesand the stronger right leg 102R receive reduced 50% references.

Turning to FIGS. 14a, 14b, 15a and 15b , examples of a leg actuator unit110 can include the joint 125, bellows actuator 130, constraint ribs135, and base plates 140. More specifically, FIG. 14a illustrates a sideview of a leg actuator unit 110 in a compressed configuration and FIG.14b illustrates a side view of the leg actuator unit 110 of FIG. 14a inan expanded configuration. FIG. 15a illustrates a cross-sectional sideview of a leg actuator unit 110 in a compressed configuration and FIG.15b illustrates a cross-sectional side view of the leg actuator unit 110of FIG. 15a in an expanded configuration.

As shown in FIGS. 14a, 14b, 15a and 15b , the joint 125 can have aplurality of constraint ribs 135 extending from and coupled to the joint125, which surround or abut a portion of the bellows actuator 130. Forexample, in some embodiments, constraint ribs 135 can abut the ends 132of the bellows actuator 130 and can define some or all of the baseplates 140 that the ends 132 of the bellows actuator 130 can pushagainst. However, in some examples, the base plates 140 can be separateand/or different elements than the constraint ribs 135 (e.g., as shownin FIG. 1). Additionally, one or more constraint ribs 135 can bedisposed between ends 132 of the bellows actuator 130. For example,FIGS. 14a, 14b, 15a and 15b illustrate one constraint rib 135 disposedbetween ends 132 of the bellows actuator 130; however, furtherembodiments can include any suitable number of constraint ribs 135disposed between ends of the bellows actuator 130, including 1, 2, 3, 4,5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 50, 100 and the like. In someembodiments, constraint ribs can be absent.

As shown in cross sections of FIGS. 15a and 15b , the bellows actuator130 can define a cavity 131 that can be filled with fluid (e.g., air),to expand the bellows actuator 130, which can cause the bellows toelongate along axis B as shown in FIGS. 14b and 15b . For example,increasing a pressure and/or volume of fluid in the bellows actuator 130shown in FIG. 14a can cause the bellows actuator 130 to expand to theconfiguration shown in FIG. 14b . Similarly, increasing a pressureand/or volume of fluid in the bellows actuator 130 shown in FIG. 15a cancause the bellows actuator 130 to expand to the configuration shown inFIG. 15b . For clarity, the use of the term “bellows” is to describe acomponent in the described actuator unit 110 and is not intended tolimit the geometry of the component. The bellows actuator 130 can beconstructed with a variety of geometries including but not limited to aconstant cylindrical tube, a cylinder of varying cross-sectional area, a3-D woven geometry that inflates to a defined arc shape, and the like.The term ‘bellows’ should not be construed to necessary include astructure having convolutions.

Alternatively, decreasing a pressure and/or volume of fluid in thebellows actuator 130 shown in FIG. 14b can cause the bellows actuator130 to contract to the configuration shown in FIG. 14a . Similarly,decreasing a pressure and/or volume of fluid in the bellows actuator 130shown in FIG. 15b can cause the bellows actuator 130 to contract to theconfiguration shown in FIG. 15a . Such increasing or decreasing of apressure or volume of fluid in the bellows actuator 130 can be performedby pneumatic system 520 and pneumatic lines 145 of the exoskeletonsystem 100, which can be controlled by the exoskeleton device 510 (seeFIG. 5).

In one preferred embodiment, the bellows actuator 130 can be inflatedwith air; however, in further embodiments, any suitable fluid can beused to inflate the bellows actuator 130. For example, gasses includingoxygen, helium, nitrogen, and/or argon, or the like can be used toinflate and/or deflate the bellows actuator 130. In further embodiments,a liquid such as water, an oil, or the like can be used to inflate thebellows actuator 130. Additionally, while some examples discussed hereinrelate to introducing and removing fluid from a bellows actuator 130 tochange the pressure within the bellows actuator 130, further examplescan include heating and/or cooling a fluid to modify a pressure withinthe bellows actuator 130.

As shown in FIGS. 14a, 14b, 15a and 15b , the constraint ribs 135 cansupport and constrain the bellows actuator 130. For example, inflatingthe bellows actuator 130 causes the bellows actuator 130 to expand alonga length of the bellows actuator 130 and also cause the bellows actuator130 to expand radially. The constraint ribs 135 can constrain radialexpansion of a portion of the bellows actuator 130. Additionally, asdiscussed herein, the bellows actuator 130 comprise a material that isflexible in one or more directions and the constraint ribs 135 cancontrol the direction of linear expansion of the bellows actuator 130.For example, in some embodiments, without constraint ribs 135 or otherconstraint structures the bellows actuator 130 would herniate or bendout of axis uncontrollably such that suitable force would not be appliedto the base plates 140 such that the arms 115, 120 would not be suitablyor controllably actuated. Accordingly, in various embodiments, theconstraint ribs 135 can be desirable to generate a consistent andcontrollable axis of expansion B for the bellows actuator 130 as theyare inflated and/or deflated.

In some examples, the bellows actuator 130 in a deflated configurationcan substantially extend past a radial edge of the constraint ribs 135and can retract during inflation to extend less past the radial edge ofthe constraint ribs 135, to extend to the radial edge of the constraintribs 135, or not to extend less past the radial edge of the constraintribs 135. For example, FIG. 15a illustrates a compressed configurationof the bellows actuator 130 where the bellows actuator 130 substantiallyextend past a radial edge of the constraint ribs 135 and FIG. 15billustrates the bellows actuator 130 retracting during inflation toextend less past the radial edge of the constraint ribs 135 in aninflated configuration of the bellows actuator 130.

Similarly, FIG. 16a illustrates a top view of a compressed configurationof bellows actuator 130 where the bellows actuator 130 substantiallyextend past a radial edge of constraint ribs 135 and FIG. 16billustrates a top view where the bellows actuator 130 retract duringinflation to extend less past the radial edge of the constraint ribs 135in an inflated configuration of the bellows actuator 130.

Constraint ribs 135 can be configured in various suitable ways. Forexample, FIGS. 16a, 16b and 17 illustrate a top view of an exampleembodiment of a constraint rib 135 having a pair of rib arms 136 thatextend from the joint structure 125 and couple with a circular rib ring137 that defines a rib cavity 138 through which a portion of the bellowsactuator 130 can extend (e.g., as shown in FIGS. 15a, 15b, 16a and 16b). In various examples, the one or more constraint ribs 135 can be asubstantially planar element with the rib arms 136 and rib ring 137being disposed within a common plane.

In further embodiments, the one or more constraint ribs 135 can have anyother suitable configuration. For example, some embodiments can have anysuitable number of rib arms 136, including one, two, three, four, five,or the like. Additionally, the rib ring 137 can have various suitableshapes and need not be circular, including one or both of an inner edgethat defines the rib cavity 138 or an outer edge of the rib ring 137.

In various embodiments, the constraining ribs 135 can be configured todirect the motion of the bellows actuator 130 through a swept path aboutsome instantaneous center (which may or may not be fixed in space)and/or to prevent motion of the bellows actuator 130 in undesireddirections, such as out-of-plane buckling. As a result, the number ofconstraining ribs 135 included in some embodiments can vary depending onthe specific geometry and loading of the leg actuator unit 110. Examplescan range from one constraining rib 135 up to any suitable number ofconstraining ribs 135; accordingly, the number of constraining ribs 135should not be taken to limit the applicability of the invention.Additionally, constraining ribs 135 can be absent in some embodiments.

The one or more constraining ribs 135 can be constructed in a variety ofways. For example the one or more constraining ribs 135 can vary inconstruction on a given leg actuator unit 110, and/or may or may notrequire attachment to the joint structure 125. In various embodiments,the constraining ribs 135 can be constructed as an integral component ofa central rotary joint structure 125. An example embodiment of such astructure can include a mechanical rotary pin joint, where theconstraining ribs 135 are connected to and can pivot about the joint 125at one end of the joint structure 125, and are attached to aninextensible outer layer of the bellows actuator 130 at the other end.In another set of embodiments, the constraining ribs 135 can beconstructed in the form of a single flexural structure that directs themotion of the bellows actuator 130 throughout the range of motion forthe leg actuator unit 110. Another example embodiment uses a flexuralconstraining rib 135 that is not connected integrally to the jointstructure 125 but is instead attached externally to a previouslyassembled joint structure 125. Another example embodiment can comprisethe constraint ribs 135 being composed of pieces of fabric wrappedaround the bellows actuator 130 and attached to the joint structure 125,acting like a hammock to restrict and/or guide the motion of the bellowsactuator 130. There are additional methods available for constructingthe constraining ribs 135 that can be used in additional embodimentsthat include but are not limited to a linkage, a rotational flexureconnected around the joint structure 125, and the like.

In some examples, a design consideration for constraining ribs 135 canbe how the one or more constraining ribs 135 interact with the bellowsactuator 130 to guide the path of the bellows actuator 130. In variousembodiments, the constraining ribs 135 can be fixed to the bellowsactuator 130 at predefined locations along the length of the bellowsactuator 130. One or more constraining ribs 135 can be coupled to thebellows actuator 130 in various suitable ways, including but not limitedto sewing, mechanical clamps, geometric interference, directintegration, and the like. In other embodiments, the constraining ribs135 can be configured such that the constraining ribs 135 float alongthe length of the bellows actuator 130 and are not fixed to the bellowsactuator 130 at predetermined connection points. In some embodiments,the constraining ribs 135 can be configured to restrict a crosssectional area of the bellows actuator 130. An example embodiment caninclude a tubular bellows actuator 130 attached to a constraining rib135 that has an oval cross section, which in some examples can be aconfiguration to reduce the width of the bellows actuator 130 at thatlocation when the bellows actuator 130 is inflated.

The bellows actuator 130 can have various functions in some embodiments,including containing operating fluid of the leg actuator unit 110,resisting forces associated with operating pressure of the leg actuatorunit 110, and the like. In various examples, the leg actuator unit 110can operate at a fluid pressure above, below or at about ambientpressure. In various embodiments, bellows actuator 130 can comprise oneor more flexible, yet inextensible or practically inextensible materialsin order to resist expansion (e.g., beyond what is desired in directionsother than an intended direction of force application or motion) of thebellows actuator 130 beyond what is desired when pressurized aboveambient pressure. Additionally, the bellows actuator 130 can comprise animpermeable or semi-impermeable material in order to contain theactuator fluid.

For example, in some embodiments, the bellows actuator 130 can comprisea flexible sheet material such as woven nylon, rubber, polychloroprene,a plastic, latex, a fabric, or the like. Accordingly, in someembodiments, bellows actuator 130 can be made of a planar material thatis substantially inextensible along one or more plane axes of the planarmaterial while being flexible in other directions. For example, FIG. 19illustrates a side view of a planar material 1900 (e.g., a fabric) thatis substantially inextensible along axis X that is coincident with theplane of the material 1900, yet flexible in other directions, includingaxis Z. In the example of FIG. 19, the material 1900 is shown flexingupward and downward along axis Z while being inextensible along axis X.In various embodiments, the material 1900 can also be inextensible alongan axis Y (not shown) that is also coincident with the plane of thematerial 1900 like axis X and perpendicular to axis X.

In some embodiments, the bellows actuator 130 can be made of anon-planar woven material that is inextensible along one or more axes ofthe material. For example, in one embodiment the bellows actuator 130can comprise a woven fabric tube. Woven fabric material can provideinextensibility along the length of the bellows actuator 130 and in thecircumferential direction. Such embodiments can still be able to beconfigured along the body of the user 101 to align with the axis of adesired joint on the body 101 (e.g., the knee 103).

In various embodiments, the bellows actuator 130 can develop itsresulting force by using a constrained internal surface length and/orexternal surface length that are a constrained distance away from eachother (e.g. due to an inextensible material as discussed above). In someexamples, such a design can allow the actuator to contract on bellowsactuator 130, but when pressurized to a certain threshold, the bellowsactuator 130 can direct the forces axially by pressing on the plates 140of the leg actuator unit 110 because there is no ability for the bellowsactuator 130 to expand further in volume otherwise due to being unableto extend its length past a maximum length defined by the body of thebellows actuator 130.

In other words, the bellows actuator 130 can comprise a substantiallyinextensible textile envelope that defines a chamber that is madefluid-impermeable by a fluid-impermeable bladder contained in thesubstantially inextensible textile envelope and/or a fluid-impermeablestructure incorporated into the substantially inextensible textileenvelope. The substantially inextensible textile envelope can have apredetermined geometry and a non-linear equilibrium state at adisplacement that provides a mechanical stop upon pressurization of thechamber to prevent excessive displacement of the substantiallyinextensible textile actuator.

In some embodiments, the bellows actuator 130 can include an envelopethat consists or consists essentially of inextensible textiles (e.g.,inextensible knits, woven, non-woven, etc.) that can prescribe varioussuitable movements as discussed herein. Inextensible textile bellowsactuator 130 can be designed with specific equilibrium states (e.g., endstates or shapes where they are stable despite increasing pressure),pressure/stiffness ratios, and motion paths. Inextensible textilebellows actuator 130 in some examples can be configured accuratelydelivering high forces because inextensible materials can allow greatercontrol over directionality of the forces.

Accordingly, some embodiments of inextensible textile bellows actuator130 can have a pre-determined geometry that produces displacement mostlyvia a change in the geometry between the uninflated shape and thepre-determined geometry of its equilibrium state (e.g., fully inflatedshape) due to displacement of the textile envelope rather than viastretching of the textile envelope during a relative increase inpressure inside the chamber; in various embodiments, this can beachieved by using inextensible materials in the construction of theenvelope of the bellows actuator 130. As discussed herein, in someexamples “inextensible” or “substantially inextensible” can be definedas expansion by no more than 10%, no more than 5%, or no more than 1% inone or more direction.

FIG. 18a illustrates a cross-sectional view of a pneumatic actuator unit110 including bellows actuator 130 in accordance with another embodimentand FIG. 18b illustrates a side view of the pneumatic actuator unit 110of FIG. 18a in an expanded configuration showing the cross section ofFIG. 18a . As shown in FIG. 18a , the bellows actuator 130 can comprisean internal first layer 132 that defines the bellows cavity 131 and cancomprise an outer second layer 133 with a third layer 134 disposedbetween the first and second layers 132, 133. Throughout thisdescription, the use of the term “layer” to describe the construction ofthe bellows actuator 130 should not be viewed as limiting to the design.The use of ‘layer’ can refer to a variety of designs including but notlimited to: a planar material sheet, a wet film, a dry film, arubberized coating, a co-molded structure, and the like.

In some examples, the internal first layer 132 can comprise a materialthat is impermeable or semi-permeable to the actuator fluid (e.g., air)and the external second layer 133 can comprise an inextensible materialas discussed herein. For example, as discussed herein, an impermeablelayer can refer to an impermeable or semi-permeable layer and aninextensible layer can refer to an inextensible or a practicallyinextensible layer.

In some embodiments comprising two or more layers, the internal layer132 can be slightly oversized compared to an inextensible outer secondlayer 133 such that the internal forces can be transferred to thehigh-strength inextensible outer second layer 133. One embodimentcomprises a bellows actuator 130 with an impermeable polyurethanepolymer film inner first layer 132 and a woven nylon braid as the outersecond layer 133.

The bellows actuator 130 can be constructed in various suitable ways infurther embodiments, which can include a single-layer design that isconstructed of a material that provides both fluid impermeability andthat is sufficiently inextensible. Other examples can include a complexbellows assembly that comprises multiple laminated layers that are fixedtogether into a single structure. In some examples, it can be necessaryto limit the deflated stack height of the bellows actuator 130 tomaximize the range of motion of the leg actuator unit 110. In such anexample, it can be desirable to select a low-thickness fabric that meetsthe other performance needs of the bellows actuator 130.

In yet another embodiment, it can be desirable to reduce frictionbetween the various layers of the bellows actuator 130. In oneembodiment, this can include the integration of a third layer 134 thatacts as an anti-abrasive and/or low friction intermediate layer betweenthe first and second layers 132, 133. Other embodiments can reduce thefriction between the first and second layers 132, 133 in alternative oradditional ways, including but not limited to the use of a wetlubricant, a dry lubricant, or multiple layers of low friction material.Accordingly, while the example of FIG. 16a illustrates an example of abellows actuator 130 comprising three layers 132, 133, 134, furtherembodiments can include a bellows actuator 130 having any suitablenumber of layers, including one, two, three, four, five, ten, fifteen,twenty-five, and the like. Such one or more layers can be coupled alongadjoining faces in part or in whole, with some examples defining one ormore cavities between layers. In such examples, material such aslubricants or other suitable fluids can be disposed in such cavities orsuch cavities can be effectively empty. Additionally, as describedherein, one or more layers (e.g., the third layer 134) need not be asheet or planar material layer as shown in some examples and can insteadcomprise a layer defined by a fluid. For example, in some embodiments,the third layer 134 can be defined by a wet lubricant, a dry lubricant,or the like.

The inflated shape of the bellows actuator 130 can be important to theoperation of the bellows actuator 130 and/or leg actuator unit 110 insome embodiments. For example, the inflated shape of the bellowsactuator 130 can be affected through the design of both an impermeableand inextensible portion of the bellows actuator 130 (e.g., the firstand second layer 132, 133). In various embodiments, it can be desirableto construct one or more of the layers 132, 133, 134 of the bellowsactuator 130 out of various two-dimensional panels that may not beintuitive in a deflated configuration.

In some embodiments, one or more impermeable layers can be disposedwithin the bellows cavity 131 and/or the bellows actuator 130 cancomprise a material that is capable of holding a desired fluid (e.g., afluid impermeable first internal layer 132 as discussed herein). Thebellows actuator 130 can comprise a flexible, elastic, or deformablematerial that is operable to expand and contract when the bellowsactuator 130 are inflated or deflated as described herein. In someembodiments, the bellows actuator 130 can be biased toward a deflatedconfiguration such that the bellows actuator 130 is elastic and tends toreturn to the deflated configuration when not inflated. Additionally,although bellows actuator 130 shown herein are configured to expandand/or extend when inflated with fluid, in some embodiments, bellowsactuator 130 can be configured to shorten and/or retract when inflatedwith fluid in some examples. Also, the term “bellows” as used hereinshould not be construed to be limiting in any way. For example the term“bellows” as used herein should not be construed to require elementssuch as convolutions or other such features (although convoluted bellowsactuator 130 can be present in some embodiments). As discussed herein,bellows actuator 130 can take on various suitable shapes, sizes,proportions and the like.

The bellows actuator 130 can vary significantly across variousembodiments, so the present examples should not be construed to belimiting. One preferred embodiment of a bellows actuator 130 includesfabric-based pneumatic actuator configured such that it provides kneeextension torque as discussed herein. Variants of this embodiment canexist to tailor the actuator to provide the desired performancecharacteristics of the actuators such as a fabric actuator that is notof a uniform cross-section. Other embodiments can use anelectro-mechanical actuator configured to provide flexion and extensiontorques at the knee instead of or in addition to a fluidic bellowsactuator 130. Various embodiments can include but are not limited todesigns that incorporate combinations of electromechanical, hydraulic,pneumatic, electro-magnetic, or electro-static for positive power ornegative power assistance of extension or flexion of a lower extremityjoint.

The actuator bellows actuator 130 can also be located in a variety oflocations as required by the specific design. One embodiment places thebellows actuator 130 of a powered knee brace component located in linewith the axis of the knee joint and positioned parallel to the jointitself. Various embodiments include but are not limited to, actuatorsconfigured in series with the joint, actuators configured anterior tothe joint, and actuators configured to rest around the joint.

Various embodiments of the bellows actuator 130 can include secondaryfeatures that augment the operation of the actuation. One suchembodiment is the inclusion of user-adjustable mechanical hard end stopsto limit the allowable range of motion to the bellows actuator 130.Various embodiments can include but are not limited to the followingextension features: the inclusion of flexible end stops, the inclusionof an electromechanical brake, the inclusion of an electro-magneticbrake, the inclusion of a magnetic brake, the inclusion of a mechanicaldisengage switch to mechanically decouple the joint from the actuator,or the inclusion of a quick release to allow for quick changing ofactuator components.

In various embodiments, the bellows actuator 130 can comprise a bellowsand/or bellows system as described in related U.S. patent applicationSer. No. 14/064,071 filed Oct. 25, 2013, which issued as U.S. Pat. No.9,821,475; as described in U.S. patent application Ser. No. 14/064,072filed Oct. 25, 2013; as described in U.S. patent application Ser. No.15/823,523 filed Nov. 27, 2017; or as described in U.S. patentapplication Ser. No. 15/472,740 filed Mar. 29, 2017.

In some applications, the design of the fluidic actuator unit 110 can beadjusted to expand its capabilities. One example of such a modificationcan be made to tailor the torque profile of a rotary configuration ofthe fluidic actuator unit 110 such that the torque changes as a functionof the angle of the joint structure 125. To accomplish this in someexamples, the cross-section of the bellows actuator 130 can bemanipulated to enforce a desired torque profile of the overall fluidicactuator unit 110. In one embodiment, the diameter of the bellowsactuator 130 can be reduced at a longitudinal center of the bellowsactuator 130 to reduce the overall force capabilities at the fullextension of the bellows actuator 130. In yet another embodiment, thecross-sectional areas of the bellows actuator 130 can be modified toinduce a desired buckling behavior such that the bellows actuator 130does not get into an undesirable configuration. In an exampleembodiment, the end configurations of the bellows actuator 130 of arotary configuration can have the area of the ends reduced slightly fromthe nominal diameter to provide for the end portions of the bellowsactuator 130 to buckle under loading until the actuator unit 110 extendsbeyond a predetermined joint angle, at which point the smaller diameterend portion of the bellows actuator 130 would begin to inflate.

In other embodiments, this same capability can be developed by modifyingthe behavior of the constraining ribs 135. As an example embodiment,using the same example bellows actuator 130 as discussed in the previousembodiment, two constraining ribs 135 can fixed to such bellows actuator130 at evenly distributed locations along the length of the bellowsactuator 130. In some examples, a goal of resisting a partially inflatedbuckling can be combated by allowing the bellows actuator 130 to closein a controlled manner as the actuator unit 110 closes. The constrainingribs 135 can be allowed to get closer to the joint structure 125 but notcloser to each other until they have bottomed out against the jointstructure 125. This can allow the center portion of the bellows actuator130 to remain in a fully inflated state which can be the strongestconfiguration of the bellows actuator 130 in some examples.

In further embodiments, it can be desirable to optimize the fiber angleof the individual braid or weave of the bellows actuator 130 in order totailor specific performance characteristics of the bellows actuator 130(e.g., in an example where a bellows actuator 130 includesinextensibility provided by a braided or woven fabric). In otherembodiments, the geometry of the bellows actuator 130 of the actuatorunit 110 can be manipulated to allow the robotic exoskeleton system 100to operate with different characteristics. Example methods for suchmodification can include but are not limited to the following: the useof smart materials on the bellows actuator 130 to manipulate themechanical behavior of the bellows actuator 130 on command; or themechanical modification of the geometry of the bellows actuator 130through means such as shortening the operating length and/or reducingthe cross sectional area of the bellows actuator 130.

In further examples, a fluidic actuator unit 110 can comprise a singlebellows actuator 130 or a combination of multiple bellows actuator 130,each with its own composition, structure, and geometry. For example,some embodiments can include multiple bellows actuator 130 disposed inparallel or concentrically on the same joint assembly 125 that can beengaged as needed. In one example embodiment, a joint assembly 125 canbe configured to have two bellows actuator 130 disposed in paralleldirectly next to each other. The exoskeleton system 100 can selectivelychoose to engage each bellows actuator 130 as needed to allow forvarious amounts of force to be output by the same fluidic actuator unit110 in a desirable mechanical configuration.

In further embodiments, a fluidic actuator unit 110 can include varioussuitable sensors to measure mechanical properties of the bellowsactuator 130 or other portions of the fluidic actuator unit 110 that canbe used to directly or indirectly estimate pressure, force, or strain inthe bellows actuator 130 or other portions of the fluidic actuator unit110. In some examples, sensors located at the fluidic actuator unit 110can be desirable due to the difficulty in some embodiments associatedwith the integration of certain sensors into a desirable mechanicalconfiguration while others may be more suitable. Such sensors at thefluidic actuator unit 110 can be operably connected to the exoskeletondevice 610 (see FIG. 6) and the exoskeleton device 610 can use data fromsuch sensors at the fluidic actuator unit 110 to control the exoskeletonsystem 100.

As discussed herein, various suitable exoskeleton systems 100 can beused in various suitable ways and for various suitable applications.However, such examples should not be construed to be limiting on thewide variety of exoskeleton systems 100 or portions thereof that arewithin the scope and spirit of the present disclosure. Accordingly,exoskeleton systems 100 that are more or less complex than the examplesof FIGS. 1-5 are within the scope of the present disclosure.

Additionally, while various examples relate to an exoskeleton system 100associated with the legs or lower body of a user, further examples canbe related to any suitable portion of a user body including the torso,arms, head, legs, or the like. Also, while various examples relate toexoskeletons, it should be clear that the present disclosure can beapplied to other similar types of technology, including prosthetics,body implants, robots, or the like. Further, while some examples canrelate to human users, other examples can relate to animal users, robotusers, various forms of machinery, or the like.

The described embodiments are susceptible to various modifications andalternative forms, and specific examples thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the described embodiments are not to belimited to the particular forms or methods disclosed, but to thecontrary, the present disclosure is to cover all modifications,equivalents, and alternatives. Additionally, elements of a givenembodiment should not be construed to be applicable to only that exampleembodiment and therefore elements of one example embodiment can beapplicable to other embodiments. Additionally, elements that arespecifically shown in example embodiments should be construed to coverembodiments that comprise, consist essentially of, or consist of suchelements, or such elements can be explicitly absent from furtherembodiments. Accordingly, the recitation of an element being present inone example should be construed to support some embodiments where suchan element is explicitly absent.

What is claimed is:
 1. A method of operating a modular exoskeletonsystem, the method comprising: monitoring, by an electronic exoskeletondevice of the modular exoskeleton system, for one or more leg actuatorunits being operably coupled to or removed from the modular exoskeletonsystem, the modular exoskeleton system comprising: a left and right legactuator unit configured to be respectively coupled to a left leg and aright leg of a user and configured to be operably coupled and removedfrom the modular exoskeleton system, the left and right leg actuatorunits each including: an upper arm and a lower arm that are rotatablycoupled via a joint, the joint positioned at a knee of the user with theupper arm coupled about an upper leg portion of the user above the kneeand with the lower arm coupled about a lower leg portion of the userbelow the knee, a bellows actuator that extends between the upper armand lower arms, and one or more sets of lines including at least a fluidline coupled to the bellows actuator configured to introduce fluid tothe bellows actuator to cause the bellows actuator to expand and movethe upper arm and lower arm and a sensor line configured to obtain datafrom one or more sensors of the leg actuator unit, the one or more setsof lines configured to be removably operably coupled to the modularexoskeleton system via one or more line couplings; determining, by theelectronic exoskeleton device of the modular exoskeleton system, thatthe left leg actuator unit has been operably coupled to the modularexoskeleton system via the one or more line couplings while the rightleg actuator unit was already operably coupled to the modularexoskeleton system and coupled to the right leg of the user;determining, by the electronic exoskeleton device of the modularexoskeleton system, that the left leg actuator unit has been coupled tothe left leg of the user; determining, by the electronic exoskeletondevice of the modular exoskeleton system, a first new operatingconfiguration based at least in part on the determination that the leftleg actuator unit has been operably coupled to the modular exoskeletonsystem via the one or more line couplings while the right leg actuatorunit was already operably coupled to the modular exoskeleton system andcoupled to the right leg of the user, the first new operatingconfiguration including a dual-knee operating configuration; setting, bythe electronic exoskeleton device of the modular exoskeleton system, thedual-knee operating configuration for the modular exoskeleton system inplace of a single-right-knee operating configuration that was previouslyset based at least in part on the right leg actuator unit being operablycoupled to the modular exoskeleton system and determined as beingcoupled to the right leg of the user; determining, by the electronicexoskeleton device of the modular exoskeleton system, that the left legactuator unit has been operably de-coupled from the modular exoskeletonsystem via the one or more line couplings while the right leg actuatorunit remains operably coupled to the modular exoskeleton system andcoupled to the right leg of the user; determining, by the electronicexoskeleton device of the modular exoskeleton system, a second newoperating configuration based at least in part on the determination thatthe left leg actuator unit has been operably de-coupled from the modularexoskeleton system via the one or more line couplings while the rightleg actuator unit remains operably coupled to the modular exoskeletonsystem and coupled to the right leg of the user, the second newoperating configuration including the single-right-knee operatingconfiguration; and setting, by the electronic exoskeleton device of themodular exoskeleton system, the single-right-knee operatingconfiguration for the modular exoskeleton system in place of thedual-knee operating configuration.
 2. The method of operating a modularexoskeleton system of claim 1, wherein the determining that the left legactuator unit has been coupled to the left leg of the user includes theelectronic exoskeleton device obtaining an identifier associated withthe left leg actuator unit, the identifier associated with informationthat indicates that the left leg actuator unit is specificallyconfigured for being coupled to the left leg of the user and not forbeing coupled to the right leg of the user.
 3. The method of operating amodular exoskeleton system of claim 1, wherein the determining that theleft leg actuator unit has been coupled to the left leg of the user isbased at least in part on a determination that the left leg actuatorunit has been operably coupled to the modular exoskeleton system via aleft leg line coupler.
 4. The method of operating a modular exoskeletonsystem of claim 1, wherein the setting the dual-knee operatingconfiguration for the modular exoskeleton system includes determiningdifferent settings of the left and right leg actuation units based ondifferent user needs between left leg and right leg of the user.
 5. Amethod of operating a modular exoskeleton system, the method comprising:monitoring for one or more leg actuator units being operably coupled toor removed from the modular exoskeleton system, the modular exoskeletonsystem comprising a left and right leg actuator unit configured to berespectively coupled to a left leg and a right leg of a user andconfigured to be operably coupled and removed from the modularexoskeleton system; determining that the left leg actuator unit has beenoperably coupled to the modular exoskeleton system while the right legactuator unit was already operably coupled to the modular exoskeletonsystem; determining that the left leg actuator unit has been associatedwith the left leg of the user; determining a first new operatingconfiguration based at least in part on the determination that the leftleg actuator unit has been operably coupled to the modular exoskeletonsystem while the right leg actuator unit was already operably coupled tothe modular exoskeleton system and associated with the right leg of theuser, the first new operating configuration including a dual-kneeoperating configuration; and setting the dual-knee operatingconfiguration for the modular exoskeleton system in place of asingle-right-knee operating configuration that was previously set basedat least in part on the right leg actuator unit being operably coupledto the modular exoskeleton system.
 6. The method of operating a modularexoskeleton system of claim 5, wherein the left and right leg actuatorunits each comprise: an upper arm and a lower arm that are rotatablycoupled via a joint, the joint positioned at a knee of the user with theupper arm coupled about an upper leg portion of the user above the kneeand with the lower arm coupled about a lower leg portion of the userbelow the knee, an actuator that extends between the upper arm and lowerarms, and one or more sets of lines configured to be removably operablycoupled to the modular exoskeleton system via one or more linecouplings.
 7. The method of operating a modular exoskeleton system ofclaim 5, wherein the left leg actuator unit is physically operablycoupled to the modular exoskeleton system via one or more linecouplings.
 8. The method of operating a modular exoskeleton system ofclaim 5, further comprising: determining that the left leg actuator unithas been operably de-coupled from the modular exoskeleton system whilethe right leg actuator unit remains operably coupled to the modularexoskeleton system; determining a second new operating configurationbased at least in part on the determination that the left leg actuatorunit has been operably de-coupled from the modular exoskeleton systemwhile the right leg actuator unit remains operably coupled to themodular exoskeleton system, the second new operating configurationincluding the single-right-knee operating configuration; and setting thesingle-right-knee operating configuration for the modular exoskeletonsystem in place of the dual-knee operating configuration.
 9. The methodof operating a modular exoskeleton system of claim 5, wherein thedetermining that the left leg actuator unit has been coupled to the leftleg of the user includes obtaining an identifier associated with theleft leg actuator unit, the identifier associated with information thatindicates that the left leg actuator unit is specifically configured forbeing coupled to the left leg of the user.
 10. The method of operating amodular exoskeleton system of claim 5, wherein the determining that theleft leg actuator unit has been coupled to the left leg of the user isbased at least in part on a determination that the left leg actuatorunit has been operably coupled to the modular exoskeleton system via aleft leg line coupler.
 11. The method of operating a modular exoskeletonsystem of claim 5, wherein the setting the dual-knee operatingconfiguration for the modular exoskeleton system includes determiningdifferent settings of the left and right leg actuation units based ondifferent user needs between left leg and right leg of the user.
 12. Amethod of operating a modular exoskeleton system, the method comprising:monitoring for one or more actuator units being operably coupled to orremoved from the modular exoskeleton system, the modular exoskeletonsystem comprising at least a first actuator unit configured to beoperably coupled and removed from the modular exoskeleton system;determining that the first actuator unit has been operably coupled tothe modular exoskeleton system; determining that the first actuator unithas been associated with a first body portion of a user; determining afirst new operating configuration based at least in part on thedetermination that the first actuator unit has been operably coupled tothe modular exoskeleton system and the determination that the firstactuator unit has been associated with the first body portion of theuser; and setting the first new operating configuration for the modularexoskeleton system.
 13. The method of operating a modular exoskeletonsystem of claim 12, further comprising determining that the firstactuator unit has been operably coupled to the modular exoskeletonsystem while a second actuator unit was already operably coupled to themodular exoskeleton system; and wherein determining the first newoperating configuration is further based at least in part on thedetermination that the first actuator unit has been operably coupled tothe modular exoskeleton system while the second actuator unit wasalready operably coupled to the modular exoskeleton system, the firstnew operating configuration including a dual-body portion operatingconfiguration.
 14. The method of operating a modular exoskeleton systemof claim 13, wherein the setting the dual-body portion operatingconfiguration for the modular exoskeleton system includes determiningdifferent settings of the first and second actuator units based ondifferent user needs between the first body portion and a second bodyportion of the user.
 15. The method of operating a modular exoskeletonsystem of claim 12, further comprising setting the first new operatingconfiguration for the modular exoskeleton system in place of a singlebody portion operating configuration that was previously set based atleast in part on a second actuator unit being operably coupled to themodular exoskeleton system.
 16. The method of operating a modularexoskeleton system of claim 12, wherein the first actuator unitcomprises: an upper arm and a lower arm that are rotatably coupled via ajoint, the joint positioned at a body-joint of the user with the upperarm coupled about an upper-portion of the user above the body-joint andwith the lower arm coupled about a lower-portion of the user below thebody joint, and an actuator.
 17. The method of operating a modularexoskeleton system of claim 12, further comprising: determining that thefirst actuator unit has been operably de-coupled from the modularexoskeleton system; determining a second new operating configurationbased at least in part on the determination that the first actuator unithas been operably de-coupled from the modular exoskeleton system; andsetting the second new operating configuration for the modularexoskeleton system.
 18. The method of operating a modular exoskeletonsystem of claim 17, further comprising determining that the firstactuator unit has been operably de-coupled from the modular exoskeletonsystem while a second actuator unit remains operably coupled to themodular exoskeleton system, the second new operating configurationincluding a single-body-portion operating configuration; and setting thesingle-body-portion operating configuration for the modular exoskeletonsystem in place of a dual-body-portion operating configuration.
 19. Themethod of operating a modular exoskeleton system of claim 12, whereinthe determining that the first actuator unit has been associated withthe first body portion of the user includes obtaining an identifierassociated with the first actuator unit, the identifier associated withinformation that indicates that the first actuator unit is specificallyconfigured for being coupled to the first body portion of the user. 20.The method of operating a modular exoskeleton system of claim 12,wherein the determining that the first actuator unit has been associatedwith the first body portion of the user is based at least in part on adetermination that the first actuator unit has been operably coupled tothe modular exoskeleton system via a first-body-portion line coupler.